Leaching assemblies, systems, and methods for processing superabrasive elements

ABSTRACT

A polycrystalline diamond element leaching assembly includes a polycrystalline diamond element, a protective leaching cup surrounding at least a portion of the polycrystalline diamond element, and a liner positioned between the polycrystalline diamond element and the protective leaching cup. A leaching assembly for processing a polycrystalline diamond element includes a protective leaching cup configured to surround at least a portion of a polycrystalline diamond element and a liner configured to be positioned between the polycrystalline diamond element and the protective leaching cup. A method of processing a polycrystalline diamond element includes assembling a polycrystalline diamond element, a liner, and a protective leaching cup such that the liner is disposed between the polycrystalline diamond element and the protective leaching cup, and exposing at least a portion of the polycrystalline diamond element to a leaching agent.

BACKGROUND

Wear-resistant, superabrasive materials are traditionally utilized for avariety of mechanical applications. For example, polycrystalline diamond(“PCD”) materials are often used in drilling tools (e.g., cuttingelements, gage trimmers, etc.), machining equipment, bearingapparatuses, wire-drawing machinery, and in other mechanical systems.Conventional superabrasive materials have found utility as superabrasivecutting elements in rotary drill bits, such as roller cone drill bitsand fixed-cutter drill bits. A conventional cutting element may includea superabrasive layer or table, such as a PCD table. The cutting elementmay be brazed, press-fit, or otherwise secured into a preformed pocket,socket, or other receptacle formed in the rotary drill bit. In anotherconfiguration, the substrate may be brazed or otherwise joined to anattachment member such as a stud or a cylindrical backing. Generally, arotary drill bit may include one or more PCD cutting elements affixed toa bit body of the rotary drill bit.

As mentioned above, conventional superabrasive materials have foundutility as bearing elements, which may include bearing elements utilizedin thrust bearing and radial bearing apparatuses. A conventional bearingelement typically includes a superabrasive layer or table, such as a PCDtable, bonded to a substrate. One or more bearing elements may bemounted to a bearing rotor or stator by press-fitting, brazing, orthrough other suitable methods of attachment. Typically, bearingelements mounted to a bearing rotor have superabrasive faces configuredto contact corresponding superabrasive faces of bearing elements mountedto an adjacent bearing stator.

Cutting elements having a PCD table may be formed and bonded to asubstrate using an ultra-high pressure, ultra-high temperature (“HPHT”)sintering process. Often, cutting elements having a PCD table arefabricated by placing a cemented carbide substrate, such as acobalt-cemented tungsten carbide substrate, into a container orcartridge with a volume of diamond particles positioned on a surface ofthe cemented carbide substrate. A number of such cartridges may beloaded into a HPHT press. The substrates and diamond particle volumesmay then be processed under HPHT conditions in the presence of acatalyst material that causes the diamond particles to bond to oneanother to form a diamond table having a matrix of bonded diamondcrystals. The catalyst material is often a metal-solvent catalyst, suchas cobalt, nickel, and/or iron, that facilitates intergrowth and bondingof the diamond crystals.

In one conventional approach, a constituent of the cemented-carbidesubstrate, such as cobalt from a cobalt-cemented tungsten carbidesubstrate, liquefies and sweeps from a region adjacent to the volume ofdiamond particles into interstitial regions between the diamondparticles during the HPHT process. The cobalt may act as a catalyst tofacilitate the formation of bonded diamond crystals. A metal-solventcatalyst may also be mixed with a volume of diamond particles prior tosubjecting the diamond particles and substrate to the HPHT process.

The metal-solvent catalyst may dissolve carbon from the diamondparticles and portions of the diamond particles that graphitize due tothe high temperatures used in the HPHT process. The solubility of thestable diamond phase in the metal-solvent catalyst may be lower thanthat of the metastable graphite phase under HPHT conditions. As a resultof the solubility difference, the graphite tends to dissolve into themetal-solvent catalyst and the diamond tends to deposit onto existingdiamond particles to form diamond-to-diamond bonds. Accordingly, diamondgrains may become mutually bonded to form a matrix of polycrystallinediamond, with interstitial regions defined between the bonded diamondgrains being occupied by the metal-solvent catalyst. In addition todissolving carbon and graphite, the metal-solvent catalyst may alsocarry tungsten, tungsten carbide, and/or other materials from thesubstrate into the PCD layer of the cutting element.

The presence of the metal-solvent catalyst and/or other materials in thediamond table may reduce the thermal stability of the diamond table atelevated temperatures. For example, the difference in thermal expansioncoefficient between the diamond grains and the solvent catalyst isbelieved to lead to chipping or cracking in the PCD table of a cuttingelement during drilling or cutting operations. The chipping or crackingin the PCD table may degrade the mechanical properties of the cuttingelement or lead to failure of the cutting element. Additionally, at hightemperatures, diamond grains may undergo a chemical breakdown orback-conversion with the metal-solvent catalyst. Further, portions ofdiamond grains may transform to carbon monoxide, carbon dioxide,graphite, or combinations thereof, thereby degrading the mechanicalproperties of the PCD material.

Accordingly, it is desirable to remove a metal-solvent catalyst from aPCD material in situations where the PCD material may be exposed to hightemperatures. Chemical leaching is often used to dissolve and removevarious materials from the PCD layer. For example, chemical leaching maybe used to remove metal-solvent catalysts, such as cobalt, from regionsof a PCD layer that may experience elevated temperatures duringdrilling, such as regions adjacent to the working surfaces of the PCDlayer.

Conventional chemical leaching techniques often involve the use ofhighly concentrated and corrosive solutions, such as highly acidicsolutions, to dissolve and remove metal-solvent catalysts frompolycrystalline diamond materials. However, in addition to dissolvingmetal-solvent catalysts from a PCD material, leaching solutions may alsodissolve any accessible portions of a substrate to which the PCDmaterial is attached. For example, highly acidic leaching solutions maydissolve any accessible portions of a cobalt-cemented tungsten carbidesubstrate, causing undesired pitting and/or other corrosion of thesubstrate surface.

In some conventional leaching techniques, a polymeric leaching cup maybe placed around a portion of a PCD element or other PCD article toprotect the substrate from a leaching solution. A polymeric leaching cupmay, for example, surround the substrate surface and a portion of thePCD layer near the substrate. Such leaching cups may, however, provideinadequate protection during leaching. For example, during loading of aPCD article into a leaching cup, a portion of the leaching cup may betorn or otherwise damaged by an edge or chamfer portion of the PCDarticle. A leaching cup damaged in such a manner may undesirably allow aleaching solution to enter between the leaching cup and the PCD articlesuch that a portion of the substrate of the PCD article is exposed tothe leaching solution. Additionally, pinholes may be formed in aleaching cup during ejection of the PCD article from a leachingapparatus following a leaching procedure. Such holes formed in theleaching cup may allow leaching solution to enter the leaching cup andcome into contact with a substrate portion of the PCD article. Exposureto a leaching solution may result in undesired corrosion and/or damageto PCD substrates.

SUMMARY

The instant disclosure is directed to exemplary leaching assemblysystems, leaching assemblies, and methods for processing apolycrystalline diamond element. According to at least one embodiment, aleaching assembly system for processing a polycrystalline diamondelement may comprise a protective leaching cup configured to surround atleast a portion of a polycrystalline diamond element and a linerconfigured to be positioned between the polycrystalline diamond elementand the protective leaching cup.

The liner may comprise a side wall, a rear wall opposite an openingdefined in the liner, and a rounded edge portion at the intersection ofthe side wall and the rear wall. The liner may be configured to surroundat least a portion of the polycrystalline diamond element such that theside wall of the liner is adjacent a side surface of the polycrystallinediamond element, the rear wall of the liner is adjacent a rear surfaceof the polycrystalline diamond element, and a gap is defined between therounded edge portion of the liner and the polycrystalline diamondelement. The liner may also be configured to contact at least one of theside portion of the polycrystalline diamond element and the rear portionof the polycrystalline diamond element. According to variousembodiments, the liner may comprise a substantially rigid material, suchas at least one of a metallic material and a polymeric material.

In at least one embodiment, the protective leaching cup may comprise aside wall having a length that exceeds a length of the side wall of theliner. The protective leaching cup may comprise a seal region configuredto contact a portion of the cutting element and an encapsulating regionconfigured to surround the liner. the seal region of the protectiveleaching cup may have a smaller diameter than the encapsulating regionof the protective leaching cup.

In various embodiments, a polycrystalline diamond element leachingassembly may comprise a polycrystalline diamond element, a protectiveleaching cup surrounding at least a portion of the polycrystallinediamond element, and a liner positioned between the polycrystallinediamond element and the protective leaching cup. In some embodiments,the liner may comprise a side wall, a rear wall opposite an openingdefined in the liner, and a rounded edge portion at the intersection ofthe side wall and the rear wall. Additionally, the polycrystallinediamond element may comprise a cutting face, a rear surface opposite thecutting face, and a side surface extending between the cutting face andthe rear surface. The liner may surround at least a portion of thepolycrystalline diamond element such that the side wall of the liner maybe adjacent a portion of the side surface of the polycrystalline diamondelement, the rear wall of the liner may be adjacent a portion of therear surface of the polycrystalline diamond element, and a gap may bedefined between the rounded edge portion of the liner and thepolycrystalline diamond element.

In at least one embodiment, the polycrystalline diamond element maycomprise a chamfer at the intersection of the side surface and the rearsurface. A gap may be defined between the rounded edge portion of theliner and the chamfer of the polycrystalline diamond element. The linermay contact at least one of the side surface of the polycrystallinediamond element and the rear surface of the polycrystalline diamondelement. According to some embodiments, the polycrystalline diamondelement may comprise a substrate and a polycrystalline diamond tablebonded to the substrate. The protective leaching cup may also comprise aseal region contacting a portion of the polycrystalline diamond table ofthe polycrystalline diamond element and an encapsulating regionsurrounding the liner and the substrate of the polycrystalline diamondelement. The liner may surround at least a portion of the substrate ofthe polycrystalline diamond element. Additionally, liner may bepositioned adjacent a portion of the polycrystalline diamond table ofthe polycrystalline diamond element.

According to various embodiments, a method of processing apolycrystalline diamond element may comprise providing a polycrystallinediamond element, assembling the polycrystalline diamond element, aliner, and a protective leaching cup such that the liner is disposedbetween the polycrystalline diamond element and the protective leachingcup, and exposing at least a portion of the polycrystalline diamondelement to a leaching agent. Positioning the liner and thepolycrystalline diamond element in the protective leaching cup maycomprise positioning a seal region of the protective leaching cup incontact with a portion of a side surface of the polycrystalline diamondelement.

Features from any of the disclosed embodiments may be used incombination with one another in accordance with the general principlesdescribed herein. These and other embodiments, features, and advantageswill be more fully understood upon reading the following detaileddescription in conjunction with the accompanying drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate a number of exemplary embodimentsand are a part of the specification. Together with the followingdescription, these drawings demonstrate and explain various principlesof the instant disclosure.

FIG. 1 is a perspective view of an exemplary superabrasive elementincluding a substrate and a superabrasive table according to at leastone embodiment.

FIG. 2 is a cross-sectional side view of the exemplary superabrasiveelement illustrated in FIG. 1.

FIG. 3 is a perspective view of an exemplary leaching assembly accordingto at least one embodiment.

FIG. 4 is a cross-sectional side view of an exemplary leaching assemblyaccording to at least one embodiment.

FIG. 5 is a cross-sectional side view of an exemplary superabrasiveelement positioned within an exemplary liner according to at least oneembodiment.

FIG. 6 is a cross-sectional side view of an exemplary superabrasiveelement leaching assembly according to at least one embodiment.

FIG. 7 is a cross-sectional side view of an exemplary superabrasiveelement leaching assembly according to at least one embodiment.

FIG. 8 is a cross-sectional side view of an exemplary superabrasiveelement leaching assembly according to at least one embodiment.

FIG. 9 is a cross-sectional side view of an exemplary superabrasiveelement positioned within an exemplary liner according to at least oneembodiment.

FIG. 10 is a cross-sectional side view of an exemplary superabrasiveelement positioned within an exemplary liner according to at least oneembodiment.

FIG. 11 is a cross-sectional side view of an exemplary superabrasiveelement positioned within an exemplary liner according to at least oneembodiment.

FIG. 12 is a cross-sectional side view of an exemplary superabrasiveelement positioned within an exemplary liner according to at least oneembodiment.

FIG. 13 is a cross-sectional side view of an exemplary superabrasiveelement positioned within an exemplary liner according to at least oneembodiment.

FIG. 14 is a cross-sectional side view of an exemplary superabrasiveelement positioned within an exemplary liner according to at least oneembodiment.

FIG. 15 is a perspective view of an exemplary drill bit according to atleast one embodiment.

FIG. 16 is a partial cut-away perspective view of an exemplary thrustbearing apparatus according to at least one embodiment.

FIG. 17 is a partial cut-away perspective view of an exemplary radialbearing apparatus according to at least one embodiment.

FIG. 18 is a partial cut-away perspective view of an exemplarysubterranean drilling system according to at least one embodiment.

FIG. 19 is a flow diagram of an exemplary method of processing apolycrystalline diamond element according to at least one embodiment.

Throughout the drawings, identical reference characters and descriptionsindicate similar, but not necessarily identical, elements. While theexemplary embodiments described herein are susceptible to variousmodifications and alternative forms, specific embodiments have beenshown by way of example in the drawings and will be described in detailherein. However, the exemplary embodiments described herein are notintended to be limited to the particular forms disclosed. Rather, theinstant disclosure covers all modifications, equivalents, andalternatives falling within the scope of the appended claims.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The instant disclosure is directed to exemplary assemblies, systems, andmethods for processing polycrystalline diamond elements. Suchpolycrystalline diamond elements may be used as cutting elements for usein a variety of applications, such as drilling tools, machiningequipment, cutting tools, and other apparatuses, without limitation.Polycrystalline diamond elements, as disclosed herein, may also be usedas bearing elements in a variety of bearing applications, such as thrustbearings, radial bearings, and other bearing apparatuses, withoutlimitation.

The terms “superabrasive” and “superhard,” as used herein, may refer toany material having a hardness that is at least equal to a hardness oftungsten carbide. For example, a superabrasive article may represent anarticle of manufacture, at least a portion of which may exhibit ahardness that is equal to or greater than the hardness of tungstencarbide. The term “cutting,” as used herein, may refer to machiningprocesses, drilling processes, boring processes, and/or any othermaterial removal process utilizing a cutting element and/or othercutting apparatus, without limitation.

FIGS. 1 and 2 illustrate an exemplary superabrasive element 10 accordingto at least one embodiment. As illustrated in FIGS. 1 and 2,superabrasive element 10 may comprise a superabrasive table 14 affixedto or formed upon a substrate 12. Superabrasive table 14 may be affixedto substrate 12 at interface 26. Superabrasive element 10 may comprise arear surface 18, a superabrasive face 20, and an element side surface15. In some embodiments, element side surface 15 may include a substrateside surface 16 formed by substrate 12 and a superabrasive side surface22 formed by superabrasive table 14. Rear surface 18 may be formed bysubstrate 12.

Superabrasive element 10 may also comprise a superabrasive face 20 and asuperabrasive chamfer 24 (i.e., sloped or angled) formed bysuperabrasive table 14. Superabrasive chamfer 24 may comprise an angularand/or rounded edge formed at the intersection of superabrasive sidesurface 22 and superabrasive face 20. Any other suitable surface shapemay also be formed at the intersection of superabrasive side surface 22and superabrasive face 20, including, without limitation, an arcuatesurface (e.g., a radius, an ovoid shape, or any other rounded shape), asharp edge, multiple chamfers/radii, a honed edge, and/or combinationsof the foregoing. At least one edge may be formed at the intersection ofsuperabrasive chamfer 24 and superabrasive face 20 and/or at theintersection of superabrasive chamfer 24 and superabrasive side surface22.

In some embodiments, superabrasive element 10 may be utilized as acutting element for a drill bit, in which superabrasive chamfer 24 actsas a cutting edge. The phrase “cutting edge” may refer, withoutlimitation, to a portion of a cutting element that is configured to beexposed to and/or in contact with a subterranean formation duringdrilling. In at least one embodiment, superabrasive element 10 may beutilized as a bearing element (e.g., with superabrasive face 20 actingas bearing surface) configured to contact oppositely facing bearingelements.

According to various embodiments, superabrasive element 10 may alsocomprise a substrate chamfer 28 formed by substrate 12. Substratechamfer 28 may comprise an angular and/or rounded edge formed at theintersection of substrate side surface 16 and rear surface 18. Any othersuitable surface shape may also be formed at the intersection ofsubstrate side surface 16 and rear surface 18, including, withoutlimitation, an arcuate surface (e.g., a radius, an ovoid shape, or anyother rounded shape), a sharp edge, multiple chamfers/radii, a honededge, and/or combinations of the foregoing. At least one edge may alsobe formed at the intersection of substrate chamfer 28 and rear surface18 and/or at the intersection of substrate chamfer 28 and substrate sidesurface 16.

Superabrasive element 10 may comprise any suitable size, shape, and/orgeometry, without limitation. According to at least one embodiment, atleast a portion of superabrasive element 10 may have a substantiallycylindrical shape. For example, superabrasive element 10 may comprise asubstantially cylindrical outer surface surrounding a central axis 29extending through superabrasive element 10, as illustrated in FIGS. 1and 2. For example, substrate side surface 16 and superabrasive sidesurface 22 may be substantially cylindrical and may have any suitablediameters relative to central axis 29, without limitation. According tovarious embodiments, substrate side surface 16 and superabrasive sidesurface 22 may have substantially the same outer diameter relative tocentral axis 29.

Substrate 12 may comprise any suitable material on which superabrasivetable 14 may be formed. In at least one embodiment, substrate 12 maycomprise a cemented carbide material, such as a cobalt-cemented tungstencarbide material and/or any other suitable material. In someembodiments, substrate 12 may include a suitable metal-solvent catalystmaterial, such as, for example, cobalt, nickel, iron, and/or alloysthereof. Substrate 12 may also include any suitable material including,without limitation, cemented carbides such as titanium carbide, niobiumcarbide, tantalum carbide, vanadium carbide, chromium carbide, and/orcombinations of any of the preceding carbides cemented with iron,nickel, cobalt, and/or alloys thereof. Superabrasive table 14 may beformed of any suitable superabrasive and/or superhard material orcombination of materials, including, for example PCD. According toadditional embodiments, superabrasive table 14 may comprise cubic boronnitride, silicon carbide, polycrystalline diamond, and/or mixtures orcomposites including one or more of the foregoing materials, withoutlimitation.

Superabrasive table 14 may be formed using any suitable technique.According to some embodiments, superabrasive table 14 may comprise a PCDtable fabricated by subjecting a plurality of diamond particles to anHPHT sintering process in the presence of a metal-solvent catalyst(e.g., cobalt, nickel, iron, or alloys thereof) to facilitateintergrowth between the diamond particles and form a PCD body comprisedof bonded diamond grains that exhibit diamond-to-diamond bondingtherebetween. For example, the metal-solvent catalyst may be mixed withthe diamond particles, infiltrated from a metal-solvent catalyst foil orpowder adjacent to the diamond particles, infiltrated from ametal-solvent catalyst present in a cemented carbide substrate, orcombinations of the foregoing. The bonded diamond grains (e.g.,sp³-bonded diamond grains), so-formed by HPHT sintering the diamondparticles, define interstitial regions with the metal-solvent catalystdisposed within the interstitial regions of the as-sintered PCD body.The diamond particles may exhibit a selected diamond particle sizedistribution.

Following sintering, various materials, such as a metal-solventcatalyst, remaining in interstitial regions within the as-sintered PCDbody may reduce the thermal stability of superabrasive table 14 atelevated temperatures. In some examples, differences in thermalexpansion coefficients between diamond grains in the as-sintered PCDbody and a metal-solvent catalyst in interstitial regions between thediamond grains may weaken portions of superabrasive table 14 that areexposed to elevated temperatures, such as temperatures developed duringdrilling and/or cutting operations. The weakened portions ofsuperabrasive table 14 may be excessively worn and/or damaged during thedrilling and/or cutting operations.

Removing the metal-solvent catalyst and/or other materials from theas-sintered PCD body may improve the heat resistance and/or thermalstability of superabrasive table 14, particularly in situations wherethe PCD material may be exposed to elevated temperatures. Ametal-solvent catalyst and/or other materials may be removed from theas-sintered PCD body using any suitable technique, including, forexample, leaching. In at least one embodiment, a metal-solvent catalyst,such as cobalt, may be removed from regions of the as-sintered PCD body,such as regions adjacent to the working surfaces of superabrasive table14. Removing a metal-solvent catalyst from the as-sintered PCD body mayreduce damage to the PCD material of superabrasive table 14 caused byexpansion of the metal-solvent catalyst.

At least a portion of a metal-solvent catalyst, such as cobalt, as wellas other materials, may be removed from at least a portion of theas-sintered PCD body using any suitable technique, without limitation.For example, chemical and/or gaseous leaching may be used to remove ametal-solvent catalyst from the as-sintered PCD body up to a desireddepth from a surface thereof. The as-sintered PCD body may be leached byimmersion in an acid, such as aqua regia, nitric acid, hydrofluoricacid, or subjected to another suitable process to remove at least aportion of the metal-solvent catalyst from the interstitial regions ofthe PCD body and form superabrasive table 14 comprising a PCD table. Forexample, the as-sintered PCD body may be immersed in the acid for about2 to about 7 days (e.g., about 3, 5, or 7 days) or for a few weeks(e.g., about 4 weeks) depending on the process employed.

Even after leaching, a residual, detectable amount of the metal-solventcatalyst may be present in the at least partially leached superabrasivetable 14. It is noted that when the metal-solvent catalyst isinfiltrated into the diamond particles from a cemented tungsten carbidesubstrate including tungsten carbide particles cemented with ametal-solvent catalyst (e.g., cobalt, nickel, iron, or alloys thereof),the infiltrated metal-solvent catalyst may carry tungsten and/ortungsten carbide therewith and the as-sintered PCD body may include suchtungsten and/or tungsten carbide therein disposed interstitially betweenthe bonded diamond grains. The tungsten and/or tungsten carbide may beat least partially removed by the selected leaching process or may berelatively unaffected by the selected leaching process.

In some embodiments, only selected portions of the as-sintered PCD bodymay be leached, leaving remaining portions of resulting superabrasivetable 14 unleached. For example, some portions of one or more surfacesof the as-sintered PCD body may be masked or otherwise protected fromexposure to a leaching solution and/or gas mixture while other portionsof one or more surfaces of the as-sintered PCD body may be exposed tothe leaching solution and/or gas mixture. Other suitable techniques maybe used for removing a metal-solvent catalyst and/or other materialsfrom the as-sintered PCD body or may be used to accelerate a chemicalleaching process. For example, exposing the as-sintered PCD body toheat, pressure, electric current, microwave radiation, and/or ultrasoundmay be employed to leach or to accelerate a chemical leaching process,without limitation. Following leaching, superabrasive table 14 maycomprise a volume of PCD material that is substantially free of ametal-solvent catalyst.

The plurality of diamond particles used to form superabrasive table 14comprising the PCD material may exhibit one or more selected sizes. Theone or more selected sizes may be determined, for example, by passingthe diamond particles through one or more sizing sieves or by any othermethod. In an embodiment, the plurality of diamond particles may includea relatively larger size and at least one relatively smaller size. Asused herein, the phrases “relatively larger” and “relatively smaller”refer to particle sizes determined by any suitable method, which differby at least a factor of two (e.g., 40 μm and 20 μm). More particularly,in various embodiments, the plurality of diamond particles may include aportion exhibiting a relatively larger size (e.g., 100 μm, 90 μm, 80 μm,70 μm, 60 μm, 50 μm, 40 μm, 30 μm, 20 μm, 15 μm, 12 μm, 10 μm, 8 μm) andanother portion exhibiting at least one relatively smaller size (e.g.,30 μm, 20 μm, 15 μm, 12 μm, 10 μm, 8 μm, 4 μm, 2 μm, 1 μm, 0.5 μm, lessthan 0.5 μm, 0.1 μm, less than 0.1 μm). In another embodiment, theplurality of diamond particles may include a portion exhibiting arelatively larger size between about 40 μm and about 15 μm and anotherportion exhibiting a relatively smaller size between about 12 μm and 2μm. Of course, the plurality of diamond particles may also include threeor more different sizes (e.g., one relatively larger size and two ormore relatively smaller sizes) without limitation.

FIGS. 3 and 4 illustrate an exemplary leaching assembly 31 according toat least one embodiment. As illustrated in FIGS. 3 and 4, leachingassembly 31 may include a protective leaching cup 30 and a liner 40 forprocessing superabrasive element 10. Protective leaching cup 30 maycomprise a rear wall 32 and a side wall 34 defining a cavity 37extending from opening 36. Protective leaching cup 30 may be formed ofany suitable material, without limitation. For example, protectiveleaching cup 30 may comprise a flexible, elastic, malleable, and/orotherwise deformable material configured to surround and/or contact atleast a portion of superabrasive element 10 and liner 40. In someembodiments, protective leaching cup 30 may include one or morepolymeric materials, such as, for example, nylon,polytetrafluoroethylene (PTFE), polyethylene, rubber, silicone, and/orother polymers, without limitation. Protective leaching cup 30 may beformed using any suitable technique. For example, protective leachingcup 30 may comprise a polymeric material that is shaped through amolding process (e.g., injection molding, blow molding, compressionmolding, drawing, etc.).

In at least one embodiment, protective leaching cup 30 may comprise amaterial that is configured to conform to an exterior portion ofsuperabrasive element 10. For example, protective leaching cup 30 mayinclude a malleable and/or elastic material that conforms to an exteriorshape of a portion of superabrasive table 14 abutting protectiveleaching cup 30, such as superabrasive side surface 22. According tosome embodiments, protective leaching cup 30 may comprise a material,such as a polymeric material, that conforms to surface imperfections ofsuperabrasive side surface 22 and/or side surface 16. Heat and/orpressure may be applied to protective leaching cup 30 to cause a portionof protective leaching cup 30 abutting superabrasive side surface 22 tomore closely conform to superabrasive side surface 22. Accordingly, aseal between superabrasive side surface 22 and a portion of protectiveleaching cup 30 abutting superabrasive side surface 22 may be improved,thereby inhibiting passage of a leaching agent between superabrasiveelement 10 and protective leaching cup 30.

Protective leaching cup 30 may comprise any suitable size, shape and/orgeometry, without limitation. In at least one embodiment, portions ofprotective leaching cup 30 may have a substantially cylindrical outerperiphery surrounding central axis 29, as illustrated in FIGS. 3 and 4.Rear wall 32 and side wall 34 may define a cavity 37 within protectiveleaching cup 30. Cavity 37 may be shaped to surround at least a portionof superabrasive element 10, as described in greater detail below withreference to FIG. 6. Opening 36 may be defined in a portion ofprotective leaching cup 30 opposite rear wall 32 such that cavity 37extends between opening 36 and rear wall 32.

As illustrated in FIG. 4, cavity 37 may be defined by an inner surfaceof side wall 34 and an inner surface of rear wall 32. According tovarious embodiments, protective leaching cup 30 may comprise a sealregion 38 and an encapsulating region 39. Seal region 38 may be adjacentopening 36 and encapsulating region 39 may extend from seal region 38and may include rear wall 32. According to some embodiments, a portionof side wall 34 in seal region 38 may have a different diameter and/orshape than a portion of side wall 34 in encapsulating region 39. Forexample, as shown in FIG. 4, a portion of side wall 34 in encapsulatingregion 39 may have an inner diameter ID₂ that is greater than an innerdiameter ID₁ of a portion of side wall 34 in seal region 38 relative tocentral axis 29.

As shown in FIGS. 3 and 4, liner 40 may comprise a rear wall 42 and aside wall 44 defining a cavity 48 configured to surround and/or contactat least a portion of superabrasive element 10. Additionally, liner 40may comprise a rounded edge portion 49 formed at an intersection of rearwall 42 and side wall 44. Rounded edge portion 49 may comprise anysuitable surface shape, such as, for example, an arcuate surface (e.g.,a radius, an ovoid shape, or any other rounded shape), multiple radii, ahoned edge, a combination arcuate and flat surface, or any combinationof the foregoing. Rear wall 42, side wall 44, and rounded edge portion49 may each be formed to any suitable shape and thickness, withoutlimitation.

Liner 40 may be formed of any suitable material. For example, liner 40may comprise a rigid or substantially rigid material. In someembodiments, liner 40 may comprise one or more metallic materials. Forexample, liner 40 may be formed of one or more refractory metalmaterials, such as niobium, tantalum, molybdenum, tungsten, rhenium,chromium, vanadium, hafnium, zirconium, and/or any other suitablemetallic material or alloy thereof. In additional embodiments, liner 40may comprise various other suitable metallic materials and/or alloysthereof, such as, for example, precious metals, platinum group metals(e.g., gold and/or platinum), iron, tin, copper, silver, bronze,aluminum, steel and/or steel alloys, or any alloys of one or more of theforegoing. In additional embodiments, liner 40 may comprise one or morepolymeric materials. For example, liner 40 may comprisepolytetrafluoroethylene (PTFE) and/or any other suitable polymer orresin, without limitation. Liner 40 may also comprise any other suitablematerial or combination of materials, including, for example, ceramic,glass, a carbon material, a metallic material, a carbon allotropematerial, a composite material, an oxide material, a carbide material,and/or any combination of the foregoing.

Liner 40 may be formed using any suitable technique. For example, liner40 may comprise a metallic material that is shaped through a molding,drawing, machining, milling, grinding, and/or any other suitablemetalworking or forming technique. According to some embodiments, adisk-shaped blank (e.g., a niobium blank) may be subjected to a drawingoperation. During such a drawing operation, a punch may be utilized toforce the disk-shaped blank into a corresponding forming die cavity. Inat least one embodiment, liner 40 may comprise a polymeric material thatis shaped using, for example, a molding operation (e.g., injectionmolding, blow molding, compression molding, drawing, etc.). In variousembodiments, a combination of a metallic material, a polymeric material,and/or any other suitable material may also be utilized to form liner40. For example, liner 40 may comprise a metallic material (e.g.,niobium, steel, etc.) having one or more surfaces coated with apolymeric layer (e.g., PTFE) and/or other suitable material. In otherembodiments, liner 40 may be formed on superabrasive element 10 as acoating by spraying, dipping, polymerization, electroplating, chemicalvapor deposition, physical vapor deposition, and/or any suitable coatingtechnique, without limitation. Such a coating may be formed onsuperabrasive element 10 so as to have rounded edge portions formedadjacent more angular portions (e.g., chamfer 28) of superabrasiveelement 10.

Liner 40 may comprise any suitable size, shape, and geometry configuredto surround at least a portion of superabrasive element 10. In at leastone embodiment, portions of liner 40 may have a substantiallycylindrical outer periphery surrounding central axis 29, as illustratedin FIGS. 3 and 4. Rear wall 42 and side wall 44 may define a cavity 48within liner 40. Cavity 48 may be shaped to surround at least a portionof superabrasive element 10, as described in greater detail below withreference to FIG. 6. An opening 46 may be defined in a portion of liner40 opposite rear wall 42 such that cavity 48 extends between opening 46and rear wall 42.

Liner 40 may be sized to fit within encapsulating region 39 ofprotective leaching cup 30. According to various embodiments, side wall44 of liner 40 may have an outer diameter OD₁ that is approximately thesame as or smaller, relative to central axis 29, than inner diameter ID₂of a portion of side wall 34 of protective leaching cup 30 inencapsulating region 39. Additionally, outer diameter OD₁ of liner 40may be greater, relative to central axis 29, than inner diameter ID₁ ofa portion of side wall 34 of protective leaching cup 30 in seal region38. As illustrated in FIG. 4, cavity 48 may be defined by an innersurface of side wall 44 and an inner surface of rear wall 42. Cavity 48of liner 40 may be sized to surround at least a portion of cuttingelement 10. For example, side wall 44 of liner 40 may have an innerdiameter ID₃ that is approximately the same as or greater than an outerdiameter OD₂ of superabrasive element 10 relative to central axis 29.

FIG. 5 illustrates a superabrasive element 10 positioned within anexemplary liner 40 according to at least one embodiment. Superabrasiveelement 10 may be positioned within liner 40 such that at least aportion of an outer periphery of superabrasive element 10 is surroundedby liner 40. For example, superabrasive element 10 may be positionedwithin liner 40 so that at least a portion of rear surface 18 ofsuperabrasive element 10 is adjacent rear wall 42 of liner 40 and/or sothat at least a portion of side surface 15, such as substrate sidesurface 16, is adjacent side wall 44 of liner 40. In some embodiments,superabrasive element 10 may contact side wall 44 and/or rear wall 42 ofliner 40. For example, superabrasive element 10 may be tightlysurrounded by liner 40 so as to secure liner 40 to superabrasive element10. For example, liner 40 may be secured around superabrasive element 10by press-fitting. In additional embodiments, superabrasive element 10may be less tightly (e.g., removably) surrounded by liner 40, therebyfacilitating insertion and/or removal of superabrasive element 10 fromliner 40. According to some embodiments, liner 40 may be bonded orotherwise adhered to at least a portion of side surface 15 and/or rearsurface 18 of superabrasive element 10.

As illustrated in FIG. 5, a gap 50 may be defined between rounded edgeportion 49 of liner 40 and substrate chamfer 28 of superabrasive element10. For example, when superabrasive element 10 is disposed within liner40 such that element side surface 15 and rear surface 18 ofsuperabrasive element 10 are respectively positioned adjacent side wall44 and rear wall 42 of liner 40, chamfer 28 of superabrasive element 10may be spaced away from an inner surface of rounded edge portion 49 soas to define gap 50.

FIG. 6 illustrates an exemplary leaching assembly 60 comprisingsuperabrasive element 10, protective leaching cup 30, and liner 40according to at least one embodiment. As shown in FIG. 6, superabrasiveelement 10 may be positioned within liner 40, and superabrasive element10 and liner 40 may both be positioned within protective leaching cup30. Superabrasive element 10 and liner 40 may be positioned withinprotective leaching cup 30 such that at least a portion of an outerperiphery of superabrasive element 10 and at least a portion of an outerperiphery of liner 40 are surrounded by protective leaching cup 30.

According to some embodiments, superabrasive element 10 and liner 40 maybe positioned within protective leaching cup 30 so that rear wall 42 ofliner 40 is adjacent rear wall 32 of protective leaching cup 30 and/orso that at least a portion of side wall 44 of liner 40 is adjacent sidewall 34 of protective leaching cup 30. Additionally, at least a portionof superabrasive element 10, such as superabrasive table 14 and/orsubstrate 12, may be positioned adjacent a portion of protectiveleaching cup 30. For example, seal region 38 of protective leaching cup30 may be configured to contact at least a portion of element sidesurface 15 of superabrasive element 10, forming a seal betweenprotective leaching cup 30 and superabrasive element 10 that ispartially or fully impermeable to various fluids, such as a leachingmaterial (e.g., a leaching solution). As shown in FIG. 6, superabrasiveelement 10 may be positioned within protective leaching cup 30 so thatseal region 38 of protective leaching cup 30 contacts and forms a sealwith at least a portion of element side surface 15, such as at least aportion of superabrasive side surface 22 and/or at least a portion ofsubstrate side surface 16. In some embodiments, at least a portion ofseal region 38 of protective leaching cup 30 may have an inner diameterID₁ that is equal to or less than (e.g., when unassembled withsuperabrasive element 10) an outer diameter OD₂ of superabrasive element10 (e.g., inner diameter ID₁ and outer diameter OD₂ illustrated in FIG.4). Accordingly, at least a portion of side wall 34 in seal region 38 ofprotective leaching cup 30 may contact and/or form a seal with at leasta portion of superabrasive element 10.

According to some embodiments, when assembled, at least a portion ofencapsulating region 39 may have an inner diameter ID₂ that is greaterthan an outer diameter OD₂ of superabrasive element 10 and greater thanor equal to an outer diameter OD₁ of liner 40 (e.g., inner diameter ID₂,outer diameter OD₁, and outer diameter OD₂ illustrated in FIG. 4). Forexample, when superabrasive element 10 and liner 40 are surrounded byprotective leaching cup 30, at least a portion of side wall 34 inencapsulating region 39 of protective leaching cup 30 may be spacedapart from superabrasive element 10 such that a space or gap is definedbetween element side surface 15 of superabrasive element 10 andencapsulating region 39 of protective leaching cup 30. In someembodiments, at least a portion of side wall 34 in encapsulating region39 of protective leaching cup 30 may be spaced apart from liner 40 suchthat a space or gap is defined between side wall 44 of liner 40 andencapsulating region 39 of protective leaching cup 30. In additionalembodiments, at least a portion of encapsulating region 39 may have aninner diameter ID₂ that is approximately the same as or less than anouter diameter OD₁ of liner 40 (e.g., inner diameter ID₂ and outerdiameter OD₁ illustrated in FIG. 4). In such embodiments, at least aportion of side wall 34 in encapsulating region 39 may contact liner 40.

According to at least one embodiment, prior to leaching, superabrasiveelement 10 may be positioned in liner 40. Subsequently, superabrasiveelement 10 and liner 40 may be loaded into and positioned withinprotective leaching cup 30 so that at least a portion of side wall 34 inseal region 38 of protective leaching cup 30 is positioned adjacent atleast a portion of element side surface 15 of superabrasive element 10,and so that rear surface 18 of superabrasive element 10 is positioned inclose proximity to rear wall 32 of protective leaching cup 30. Roundededge portion 49 of liner 40 may facilitate loading of superabrasiveelement 10 and liner 40 into protective leaching cup 30. Moreover,rounded edge portion 49 of liner 40 may prevent tearing or otherwisedamaging protective leaching cup 30 (e.g., seal region 38) duringloading. For example, rounded edge portion 49 of liner 40 may comprise amore rounded and/or gently curving surface in comparison with substratechamfer 28 of superabrasive element 10, thereby reducing a potential fortearing and/or damaging protective leaching cup 30 (e.g., seal region38) during loading. Additionally, in some embodiments, rounded edgeportion 49 may be formed of a material that presents a lower potentialfor tearing and/or damaging protective leaching cup 30 during loading incomparison with a material, for example cobalt-cemented tungstencarbide, forming substrate 12 of superabrasive element 10. According tosome embodiments, liner 40 may circumferentially surround and/or abut aperipheral portion of superabrasive element 10 with respect to centralaxis 29. In at least one embodiment, liner 40 may comprise one or moreseparate segments spaced circumferentially around at least a portion ofsuperabrasive element 10.

In certain embodiments, prior to loading superabrasive element 10 andliner 40 into protective leaching cup 30, protective leaching cup 30 maybe preheated to an elevated temperature. For example, protectiveleaching cup 30 may be heated to a softening point at which the materialforming protective leaching cup 30 is suitably softened. Heatingprotective leaching cup 30 to a suitable temperature may facilitatepositioning of superabrasive element 10 within protective leaching cup30. For example, heating protective leaching cup 30 to a suitabletemperature may cause protective leaching cup 30 to expand and/orprovide an enhanced ability to deform to ease the placement andpositioning of superabrasive element 10 within protective leaching cup30 and to prevent portions of protective leaching cup 30 from beingdamaged by superabrasive element 10 and/or liner 40 during loading.Heating protective leaching cup 30 may also enable a more secure oreffective seal to be formed between protective leaching cup 30 andsuperabrasive element 10, thereby further inhibiting passage of aleaching agent between protective leaching cup 30 and superabrasiveelement 10. Protective leaching cup 30 may be heated to any temperaturesuitable for softening the material forming protective leaching cup 30to a desired extent. In at least one embodiment, a protective leachingcup 30 comprising a polyethylene material, such as linear low-densitypolyethylene (LLDPE), may be heated to a temperature of between about130° F. and about 180° F.

According to various embodiments disclosed herein, superabrasive element10 may be processed prior to loading superabrasive element 10 into liner40 and protective leaching cup 30 in order to provide a smoother surfaceon an exterior portion of superabrasive element 10. For example,exterior portions of superabrasive table 14 that come into contact withprotective leaching cup 30, such as portions of element side surface 15including superabrasive side surface 22 of superabrasive table 14 and/orsubstrate side surface 16 of substrate 12, may be processed to reducesurface imperfections. Superabrasive side surface 22 and/or substrateside surface 16 of superabrasive element 10 may be smoothed and/orpolished using any suitable mechanical, chemical, and/or electricalprocessing technique to reduce surface imperfections or improve surfacefinish, without limitation. For example, superabrasive side surface 22may be smoothed and/or polished by grinding, lapping, milling,polishing, and/or any other suitable mechanical processing technique. Byway of example, U.S. Pat. Nos. 5,967,250; 6,145,608; 5,653,300;5,447,208; and 5,944,129, the disclosure of each of which isincorporated herein, in its entirety, by this reference, disclosesuperabrasive elements having smoothed surface portions.

In at least one embodiment, a peripheral surface portion ofsuperabrasive element 10, such as at least a portion of superabrasiveside surface 22 and/or substrate side surface 16, may be mechanicallysmoothed and/or polished using a centerless grinder to a surfaceroughness of less than approximately 40 μin. In some embodiments, atleast a portion of element side surface 15 of superabrasive element 10may be smoothed to a surface roughness (e.g., mean roughness or rootmean square roughness) of between approximately 10 μin and approximately20 μin, as measured. In additional embodiments, at least a portion ofelement side surface 15 of superabrasive element 10 may be smoothed to asurface roughness of less than approximately 10 μin.

In certain embodiments, at least a portion of superabrasive side surface22 and/or substrate side surface 16 may be chemically smoothed and/orpolished by exposing superabrasive side surface 22 and/or substrate sidesurface 16 to a corrosive solution, such as a strongly acidic solution,that reduces surface imperfections on superabrasive side surface 22and/or substrate side surface 16. In other embodiments, superabrasiveside surface 22 and/or substrate side surface 16 may be platedelectrolytically and/or using an electroless plating technique (e.g.,chemical or auto-catalytic plating). In some embodiments, a portion ofprotective leaching cup 30, such as side wall 34 in seal region 38, mayoptionally be smoothed and/or polished using any suitable mechanical,chemical, and/or electrical processing technique.

Due to the improved smoothness of superabrasive side surface 22,substrate side surface 16 and/or at least a portion of protectiveleaching cup 30, a seal between superabrasive side surface 22 and/orsubstrate side surface 16 and a portion of protective leaching cup 30,such as side wall 34 in seal region 38, abutting superabrasive sidesurface 22 and/or substrate side surface 16 may be improved, therebyinhibiting passage of a leaching agent between superabrasive element 10and protective leaching cup 30. Materials forming protective leachingcup 30 may also be selected and processed so as to improve a sealbetween at least a portion of superabrasive element 10 and protectiveleaching cup 30. By way of example, U.S. Patent Application PublicationNo. 2011/0056141 A1, the disclosure of which is incorporated herein, inits entirety, by this reference, discloses processes and materials forforming protective layers over superabrasive elements.

Subsequent to loading superabrasive element 10 and liner 40 intoprotective leaching cup 30 and prior to leaching, at least a portion oftrapped gases, such as air and/or other gases, may be at least partiallyevacuated from between superabrasive element 10 and/or liner 40 andprotective leaching cup 30. For example, portions of side wall 34 may bepushed outward away from superabrasive element 10 and liner 40 so as tofacilitate evacuation of gases trapped within protective leaching cup30.

By maintaining a seal between superabrasive element 10 and protectiveleaching cup 30 during leaching, portions of superabrasive element 10may be prevented or inhibited from being exposed to a leaching agentduring leaching, thereby preventing damage, such as corrosion damage, tocertain regions of superabrasive element 10, such as substrate 12.Additionally, various regions of superabrasive element 10, such assuperabrasive face 20 and/or superabrasive chamfer 24, may not becovered by protective leaching cup 30 and may remain exposed to aleaching agent during leaching, enabling leaching of such regions toachieve a desired leach depth configuration.

Liner 40, which surrounds at least a portion of superabrasive element10, including at least a portion of substrate 12, may additionallyprevent a leaching agent from contacting substrate 12 during and/orfollowing leaching. For example, pinholes, which may be formed inprotective leaching cup 30 during ejection of superabrasive element 10from a leaching apparatus following a leaching procedure, may allow aleaching agent to contact liner 40. Rear wall 42 of liner 40, which isdisposed between rear wall 32 of protective leaching cup 30 and rearsurface 18 of superabrasive element 10, may inhibit or prevent aleaching agent, such as a leaching agent entering protective leachingcup 30 through rear wall 32, from contacting rear surface 18 ofsuperabrasive element 10. Rounded edge portion 49 and side wall 44 ofliner 30 may further prevent a leaching agent from contacting substratechamfer 28 and/or at least a portion of substrate side surface 16 ofsuperabrasive element 10. Accordingly, liner 40 may further inhibit orprevent damage, such as corrosion damage, to various regions ofsuperabrasive element 10, such as substrate 12, during and/or followingleaching.

FIGS. 7 and 8 illustrate exemplary leaching assemblies according tovarious embodiments. FIG. 7 shows an exemplary leaching assembly 160comprising superabrasive element 110, protective leaching cup 130, andliner 140 according to at least one embodiment. Liner 140 and protectiveleaching cup 130 may be utilized for processing superabrasive elementshaving various surface configurations formed at an intersection of aside surface and a rear surface.

As shown in FIG. 7, superabrasive element 110 may comprise asuperabrasive table 114 affixed to or formed upon a substrate 112.Superabrasive table 114 may be affixed to substrate 112 at interface126. Superabrasive element 110 may comprise a rear surface 118, asuperabrasive face 120, and an element side surface 115. In someembodiments, element side surface 115 may include a substrate sidesurface 116 formed by substrate 112 and a superabrasive side surface 122formed by superabrasive table 114. Rear surface 118 may be formed bysubstrate 112. Superabrasive element 110 may also comprise asuperabrasive face 120 formed by superabrasive table 114.

According to various embodiments, superabrasive element 110 may alsocomprise a substrate edge 154 formed by substrate 112. In someembodiments, substrate edge 154 may comprise an angular and/or roundededge formed at the intersection of substrate side surface 116 and rearsurface 118. Any other suitable surface shape may also be formed at theintersection of substrate side surface 116 and rear surface 118,including, without limitation, an arcuate surface (e.g., a radius, anovoid shape, or any other rounded shape), a sharp edge, a honed edge,and/or combinations of the foregoing. Accordingly to at least oneembodiment, superabrasive element 110 may comprise a superabrasive edge124 formed by superabrasive table 114. In some embodiments,superabrasive edge 124 may comprise an angular and/or rounded edge orany other suitable surface shape, including, without limitation, anarcuate surface (e.g., a radius, an ovoid shape, or any other roundedshape), a sharp edge, a honed edge, and/or combinations of theforegoing, formed at the intersection of superabrasive side surface 122and superabrasive face 120.

Protective leaching cup 130 may comprise a rear wall 132 and a side wall134 defining a cavity 137 extending from opening 136. According tovarious embodiments, protective leaching cup 130 may comprise a sealregion 138 and an encapsulating region 139. Seal region 138 may beadjacent opening 136 and encapsulating region 139 may extend from sealregion 138 and may include rear wall 132. According to some embodiments,a portion of side wall 134 in seal region 138 may have a differentdiameter and/or shape than a portion of side wall 134 in encapsulatingregion 139. For example, a portion of side wall 134 in encapsulatingregion 139 may have an inner diameter that is greater than an innerdiameter of a portion of side wall 134 in seal region 138.

Liner 140 may comprise a rear wall 142 and a side wall 144 defining acavity 148 configured to surround and/or contact at least a portion ofsuperabrasive element 110. Additionally, liner 140 may comprise arounded edge portion 149 formed at an intersection of rear wall 142 andside wall 144. Rounded edge portion 149 may comprise any suitablesurface shape, such as, for example, an arcuate surface (e.g., aradius), multiple radii, a honed edge, a combination arcuate and flatsurface, or any combination of the foregoing. Rear wall 142, side wall144, and rounded edge portion 149 may each be formed to any suitableshape and thickness, without limitation.

Liner 140 may be formed of any suitable material. For example, liner 140may comprise a rigid or substantially rigid material. In someembodiments, liner 140 may comprise one or more metallic materials. Forexample, liner 140 may be formed of one or more refractory metalmaterials, such as niobium, tantalum, molybdenum, tungsten, rhenium,chromium, vanadium, hafnium, zirconium, and/or any other suitablemetallic material or alloy thereof. In additional embodiments, liner 140may comprise various other suitable metallic materials and/or alloysthereof, such as, for example, precious metals, platinum group metals(e.g., gold and/or platinum), iron, tin, copper, silver, bronze,aluminum, steel and/or steel alloys, or any alloys of one or more of theforegoing. In additional embodiments, liner 140 may comprise one or morepolymeric materials. For example, liner 140 may comprisepolytetrafluoroethylene (PTFE) and/or any other suitable polymer orresin, without limitation. Liner 140 may also comprise any othersuitable material or combination of materials, including, for example,ceramic, glass, a carbon material, a metallic material, a carbonallotrope material, a composite material, an oxide material, a carbidematerial, and/or any combination of the foregoing.

Liner 140 may be formed using any suitable technique. For example, liner140 may comprise a metallic material that is shaped through a molding,drawing, machining, milling, grinding, and/or any other suitablemetalworking or forming technique. According to some embodiments, agenerally disk-shaped blank (e.g., a niobium blank) may be subjected toa drawing operation. During such a drawing operation, a punch may beutilized to force the disk-shaped blank into a corresponding forming diecavity. In at least one embodiment, liner 140 may comprise a polymericmaterial that is shaped using, for example, a molding operation (e.g.,injection molding, blow molding, compression molding, drawing, etc.). Invarious embodiments, a combination of a metallic material, a polymericmaterial, and/or any other suitable material may also be utilized toform liner 140. For example, liner 140 may comprise a metallic material(e.g., niobium, steel, etc.) having one or more surfaces coated with apolymeric layer (e.g., PTFE) and/or other suitable material. In otherembodiments, liner 140 may be formed on superabrasive element 10 as acoating by spraying, dipping, polymerization, electroplating, chemicalvapor deposition, physical vapor deposition, and/or any suitable coatingtechnique, without limitation. Such a coating may be formed onsuperabrasive element 10 so as to have rounded edge portions formedadjacent more angular portions (e.g., chamfer 28) of superabrasiveelement 10.

Liner 140 may comprise any suitable size, shape, and geometry configuredto surround at least a portion of superabrasive element 110. In at leastone embodiment, portions of liner 140 may have a substantiallycylindrical outer periphery. Rear wall 142 and side wall 144 may definea cavity 148 within liner 140. Cavity 148 may be shaped to surround atleast a portion of superabrasive element 110. An opening 146 may bedefined in a portion of liner 140 opposite rear wall 142 such thatcavity 148 extends between opening 146 and rear wall 142. According toat least one embodiment, liner 140 may be sized to fit withinencapsulating region 139 of protective leaching cup 130.

As shown in FIG. 7, superabrasive element 110 may be positioned withinliner 140, and superabrasive element 110 and liner 140 may both bepositioned within protective leaching cup 130. Superabrasive element 110may be positioned within liner 140 such that at least a portion of anouter periphery of superabrasive element 110 is surrounded by protectiveliner 140. For example, superabrasive element 110 may be positionedwithin liner 140 so that at least a portion of rear surface 118 ofsuperabrasive element 110 is near rear wall 142 of liner 140 and/or sothat at least a portion of side surface 115 of superabrasive element 110is adjacent side wall 144 of liner 140. For example, side wall 144 ofliner 140 may be disposed adjacent substrate side surface 116.

In some embodiments, superabrasive element 110 may contact side wall 144of liner 140. For example, superabrasive element 110 may be tightlysurrounded by liner 140 so as to secure liner 140 to superabrasiveelement 110. For example, liner 140 may be secured around superabrasiveelement 110 by press-fitting. According to some embodiments, liner 140may be bonded or otherwise adhered to at least a portion of side surface115 and/or rear surface 118 of superabrasive element 110. In additionalembodiments, superabrasive element 110 may be less tightly (e.g.,removably) surrounded by liner 140, thereby facilitating insertionand/or removal of superabrasive element 110 from liner 140. In someembodiments, liner 140 may be shaped to conform to at least a portion ofelement side surface 115, rear surface 118, and/or substrate edge 154such that rear surface 118 of superabrasive element 110 is disposedadjacent to or in contact with at least a portion of rear wall 142 ofliner 140 when superabrasive element 110 is disposed within liner 140.In additional embodiments, a gap may be defined between rear wall 142 ofliner 140 and rear surface 118 of superabrasive element 110. Accordingto some embodiments, liner 140 may circumferentially surround and/orabut a peripheral portion of superabrasive element 10 with respect tocentral axis 29. In at least one embodiment, liner 140 may comprise oneor more separate segments spaced circumferentially around at least aportion of superabrasive element 10.

Superabrasive element 110 and liner 140 may be positioned withinprotective leaching cup 130 such that at least a portion of an outerperiphery of superabrasive element 110 and at least a portion of anouter periphery of liner 140 are surrounded by protective leaching cup130. According to some embodiments, superabrasive element 110 and liner140 may be positioned within protective leaching cup 130 so that rearwall 142 of liner 140 is adjacent rear wall 132 of protective leachingcup 130 and/or so that at least a portion of side wall 144 of liner 140is adjacent side wall 134 of protective leaching cup 130. Additionally,at least a portion of superabrasive element 110, such as superabrasivetable 114 and/or substrate 112, may be positioned adjacent a portion ofprotective leaching cup 130. For example, seal region 138 of protectiveleaching cup 130 may be configured to contact at least a portion ofelement side surface 115 of superabrasive element 110, forming a sealbetween protective leaching cup 130 and superabrasive element 110 thatis partially or fully impermeable to various fluids, such as a leachingmaterial (e.g., a leaching solution).

As shown in FIG. 7, superabrasive element 110 may be positioned withinprotective leaching cup 130 so that seal region 138 of protectiveleaching cup 130 contacts and forms a seal with at least a portion ofelement side surface 115, such as at least a portion of superabrasiveside surface 122 and/or at least a portion of substrate side surface116. In some embodiments, at least a portion of seal region 138 ofprotective leaching cup 130 may have an inner diameter that is equal toor less than (e.g., when unassembled with superabrasive element 110) anouter diameter of superabrasive element 110. Accordingly, at least aportion of side wall 134 in seal region 138 of protective leaching cup130 may contact and/or form a seal with at least a portion ofsuperabrasive element 110.

At least a portion of seal region 138 of protective leaching cup 130which does not contact superabrasive element 110 may extend between aportion of superabrasive table 114, such as superabrasive edge 124, andopening 136 following loading of superabrasive element 110 and liner 140into protective leaching cup 130. Seal region 138 of protective leachingcup 130 may be configured to contact a portion of superabrasive element110 and maintain a seal between protective leaching cup 130 andsuperabrasive element 110 during and/or following exposure of at least aportion of superabrasive element 110 to a leaching agent. For example,seal region 138 is configured to maintain contact with superabrasiveside surface 122 of superabrasive table 114 in a situation wheresuperabrasive element 110 migrates toward opening 136 (e.g., during aleaching process).

According to at least one embodiment, rounded edge portion 149 of liner140 may prevent tearing or otherwise damaging protective leaching cup130 (e.g., seal region 138) during loading. For example, rounded edgeportion 149 of liner 140 may comprise a more rounded and/or gentlycurving surface in comparison with substrate edge 128 of superabrasiveelement 110, thereby reducing a potential for tearing and/or damagingprotective leaching cup 130 (e.g., seal region 138) during loading.Additionally, in some embodiments, rounded edge portion 149 may beformed of a material that presents a lower potential for tearing and/ordamaging protective leaching cup 130 during loading in comparison with amaterial, for example cobalt-cemented tungsten carbide, formingsubstrate 112 of superabrasive element 110.

In certain embodiments, prior to loading superabrasive element 110 andliner 140 into protective leaching cup 130, protective leaching cup 130may be preheated to an elevated temperature. For example, protectiveleaching cup 130 may be heated to a softening point at which thematerial forming protective leaching cup 130 is suitably softened so asto facilitate positioning of superabrasive element 110 within protectiveleaching cup 130.

According to various embodiments disclosed herein, superabrasive element110 may be processed prior to loading superabrasive element 110 intoliner 140 and protective leaching cup 130 in order to provide a smoothersurface on an exterior portion of superabrasive element 110. Forexample, exterior portions of superabrasive table 114 that come intocontact with protective leaching cup 130, such as portions of elementside surface 115 including superabrasive side surface 122 ofsuperabrasive table 114 and/or substrate side surface 116 of substrate112, may be processed to reduce surface imperfections. In someembodiments, a portion of protective leaching cup 130, such as side wall134 in seal region 138, may optionally be smoothed and/or polished usingany suitable mechanical, chemical, and/or electrical processingtechnique. Due to the improved smoothness of superabrasive side surface122, substrate side surface 116 and/or at least a portion of protectiveleaching cup 130, a seal between superabrasive side surface 122 and/orsubstrate side surface 116 and a portion of protective leaching cup 130,such as side wall 134 in seal region 138, abutting superabrasive sidesurface 122 and/or substrate side surface 116 may be improved, therebyinhibiting passage of a leaching agent between superabrasive element 110and protective leaching cup 130. Materials forming protective leachingcup 130 may also be selected and processed so as to improve a sealbetween at least a portion of superabrasive element 110 and protectiveleaching cup 130.

Subsequent to loading superabrasive element 110 and liner 140 intoprotective leaching cup 130 and prior to leaching, at least a portion oftrapped gases, such as air and/or other gases, may be at least partiallyevacuated from between superabrasive element 110 and/or liner 140 andprotective leaching cup 130. For example, portions of side wall 134 maybe pushed outward away from superabrasive element 110 and liner 140 soas to facilitate evacuation of gases trapped within protective leachingcup 130.

By maintaining a seal between superabrasive element 110 and protectiveleaching cup 130 during leaching, portions of superabrasive element 110may be prevented or inhibited from being exposed to a leaching agentduring leaching, thereby preventing damage, such as corrosion damage, tocertain regions of superabrasive element 110, such as substrate 112.Additionally, various regions of superabrasive element 110, such assuperabrasive face 120 and/or superabrasive edge 124, may not be coveredby protective leaching cup 130 and may remain exposed to a leachingagent during leaching, enabling leaching of such regions to achieve adesired leach depth configuration.

Liner 140, which surrounds at least a portion of superabrasive element110, including at least a portion of substrate 112, may additionallyprevent a leaching agent from contacting substrate 112 during and/orfollowing leaching. For example, pinholes, which may be formed inprotective leaching cup 130 during ejection of superabrasive element 110from a leaching apparatus following a leaching procedure, may allow aleaching agent to contact liner 140. Rear wall 142 of liner 140, whichis disposed between rear wall 132 of protective leaching cup 130 andrear surface 118 of superabrasive element 110, may inhibit or prevent aleaching agent, such as a leaching agent entering protective leachingcup 130 through rear wall 132, from contacting rear surface 118 ofsuperabrasive element 110. Rounded edge portion 149 and side wall 144 ofliner 130 may further prevent a leaching agent from contacting substratechamfer 128 and/or at least a portion of substrate side surface 116 ofsuperabrasive element 110. Accordingly, liner 140 may further inhibit orprevent damage, such as corrosion damage, to various regions ofsuperabrasive element 110, such as substrate 112, during and/orfollowing leaching.

FIG. 8 shows an exemplary leaching assembly 260 comprising superabrasiveelement 110, protective leaching cup 230, and liner 140 according tovarious embodiments. Liner 140 and protective leaching cup 230 may beutilized for processing superabrasive elements having various surfaceconfigurations formed at an intersection of a side surface and a rearsurface.

As shown in FIG. 8, superabrasive element 110 may comprise a substrateedge 154 formed by substrate 112. In some embodiments, substrate edge154 may comprise an angular and/or rounded edge formed at theintersection of substrate side surface 116 and rear surface 118. Anyother suitable surface shape may also be formed at the intersection ofsubstrate side surface 116 and rear surface 118, including, withoutlimitation, an arcuate surface (e.g., a radius, an ovoid shape, or anyother rounded shape), a sharp edge, a honed edge, and/or combinations ofthe foregoing. Accordingly to at least one embodiment, superabrasiveelement 110 may comprise a superabrasive edge 124 formed bysuperabrasive table 114. In some embodiments, superabrasive edge 124 maycomprise an angular and/or rounded edge or any other suitable surfaceshape, including, without limitation, an arcuate surface (e.g., aradius, an ovoid shape, or any other rounded shape), a sharp edge, ahoned edge, and/or combinations of the foregoing, formed at theintersection of superabrasive side surface 122 and superabrasive face120.

Protective leaching cup 230 may comprise a rear wall 232 and a side wall234 defining a cavity 237 extending from opening 236. According tovarious embodiments, protective leaching cup 230 may comprise a sealregion 238 and an encapsulating region 239. Seal region 238 may beadjacent opening 236 and encapsulating region 239 may extend from sealregion 238 and may include rear wall 232. According to some embodiments,a portion of side wall 234 in seal region 238 may have a differentdiameter and/or shape than a portion of side wall 234 in encapsulatingregion 239. For example, a portion of side wall 234 in encapsulatingregion 239 may have an inner diameter that is greater than an innerdiameter of a portion of side wall 234 in seal region 238.

Liner 140 may comprise a rear wall 142 and a side wall 144 defining acavity 148 configured to surround and/or contact at least a portion ofsuperabrasive element 110. Additionally, liner 140 may comprise arounded edge portion 149 formed at an intersection of rear wall 142 andside wall 144. Rounded edge portion 149 may comprise any suitablesurface shape, such as, for example, an arcuate surface (e.g., aradius), multiple radii, a honed edge, a combination arcuate and flatsurface, or any combination of the foregoing. Rear wall 142, side wall144, and rounded edge portion 149 may each be formed to any suitableshape and thickness, without limitation.

As shown in FIG. 8, superabrasive element 110 may be positioned withinliner 140, and superabrasive element 110 and liner 140 may both bepositioned within protective leaching cup 230. Superabrasive element 110may be positioned within liner 140 such that at least a portion of anouter periphery of superabrasive element 110 is surrounded by protectiveliner 140. For example, superabrasive element 110 may be positionedwithin liner 140 so that at least a portion of rear surface 118 ofsuperabrasive element 110 is near rear wall 142 of liner 140 and/or sothat at least a portion of side surface 115 of superabrasive element 110is adjacent side wall 144 of liner 140. For example, side wall 144 ofliner 140 may be disposed adjacent substrate side surface 116.

In some embodiments, superabrasive element 110 may contact side wall 144of liner 140. For example, superabrasive element 110 may be tightlysurrounded by liner 140 so as to secure liner 140 to superabrasiveelement 110. For example, liner 140 may be secured around superabrasiveelement 110 by press-fitting. According to some embodiments, liner 140may be bonded or otherwise adhered to at least a portion of side surface115 and/or rear surface 118 of superabrasive element 110. In additionalembodiments, superabrasive element 110 may be less tightly (e.g.,removably) surrounded by liner 140, thereby facilitating insertionand/or removal of superabrasive element 110 from liner 140. In someembodiments, liner 140 may be shaped to conform to at least a portion ofelement side surface 115, rear surface 118, and/or substrate edge 154such that rear surface 118 of superabrasive element 110 is disposedadjacent to or in contact with at least a portion of rear wall 142 ofliner 140 when superabrasive element 110 is disposed within liner 140.In additional embodiments, a gap may be defined between rear wall 142 ofliner 140 and rear surface 118 of superabrasive element 110. Accordingto some embodiments, liner 140 may circumferentially surround and/orabut a peripheral portion of superabrasive element 10 with respect tocentral axis 29. In at least one embodiment, liner 140 may comprise oneor more separate segments spaced circumferentially around at least aportion of superabrasive element 10.

Superabrasive element 110 and liner 140 may be positioned withinprotective leaching cup 230 such that at least a portion of an outerperiphery of superabrasive element 110 and at least a portion of anouter periphery of liner 140 are surrounded by protective leaching cup230. According to some embodiments, superabrasive element 110 and liner140 may be positioned within protective leaching cup 230 so that rearwall 142 of liner 140 is adjacent rear wall 232 of protective leachingcup 230 and/or so that at least a portion of side wall 144 of liner 140is adjacent side wall 234 of protective leaching cup 230. Additionally,at least a portion of superabrasive element 110, such as superabrasivetable 114 and/or substrate 112, may be positioned adjacent a portion ofprotective leaching cup 230. For example, seal region 138 of protectiveleaching cup 230 may be configured to contact at least a portion ofelement side surface 115 of superabrasive element 110, forming a sealbetween protective leaching cup 230 and superabrasive element 110 thatis partially or fully impermeable to various fluids, such as a leachingmaterial (e.g., a leaching solution).

As shown in FIG. 8, superabrasive element 110 may be positioned withinprotective leaching cup 230 so that seal region 238 of protectiveleaching cup 230 contacts and forms a seal with at least a portion ofelement side surface 115, such as at least a portion of superabrasiveside surface 122 and/or at least a portion of substrate side surface116. In some embodiments, at least a portion of seal region 238 ofprotective leaching cup 230 may have an inner diameter that is equal toor less than (e.g., when unassembled with superabrasive element 110) anouter diameter of superabrasive element 110. Accordingly, at least aportion of side wall 234 in seal region 238 of protective leaching cup230 may contact and/or form a seal with at least a portion ofsuperabrasive element 110.

According to at least one embodiment, rounded edge portion 149 of liner140 may prevent tearing or otherwise damaging protective leaching cup230 (e.g., seal region 238) during loading. For example, rounded edgeportion 149 of liner 140 may comprise a more rounded and/or gentlycurving surface in comparison with substrate edge 128 of superabrasiveelement 110, thereby reducing a potential for tearing and/or damagingprotective leaching cup 230 (e.g., seal region 238) during loading.Additionally, in some embodiments, rounded edge portion 149 may beformed of a material that presents a lower potential for tearing and/ordamaging protective leaching cup 230 during loading in comparison with amaterial, for example cobalt-cemented tungsten carbide, formingsubstrate 112 of superabrasive element 110.

In certain embodiments, prior to loading superabrasive element 110 andliner 140 into protective leaching cup 230, protective leaching cup 230may be preheated to an elevated temperature. For example, protectiveleaching cup 230 may be heated to a softening point at which thematerial forming protective leaching cup 230 is suitably softened so asto facilitate positioning of superabrasive element 110 within protectiveleaching cup 230.

According to various embodiments disclosed herein, superabrasive element110 may be processed prior to loading superabrasive element 110 intoliner 140 and protective leaching cup 230 in order to provide a smoothersurface on an exterior portion of superabrasive element 110. Forexample, exterior portions of superabrasive table 114 that come intocontact with protective leaching cup 230, such as portions of elementside surface 115 including superabrasive side surface 122 ofsuperabrasive table 114 and/or substrate side surface 116 of substrate112, may be processed to reduce surface imperfections. In someembodiments, a portion of protective leaching cup 230, such as side wall234 in seal region 238, may optionally be smoothed and/or polished usingany suitable mechanical, chemical, and/or electrical processingtechnique. Due to the improved smoothness of superabrasive side surface122, substrate side surface 116 and/or at least a portion of protectiveleaching cup 230, a seal between superabrasive side surface 122 and/orsubstrate side surface 116 and a portion of protective leaching cup 230,such as side wall 234 in seal region 238, abutting superabrasive sidesurface 122 and/or substrate side surface 116 may be improved, therebyinhibiting passage of a leaching agent between superabrasive element 110and protective leaching cup 230. Materials forming protective leachingcup 230 may also be selected and processed so as to improve a sealbetween at least a portion of superabrasive element 110 and protectiveleaching cup 230.

Subsequent to loading superabrasive element 110 and liner 140 intoprotective leaching cup 230 and prior to leaching, at least a portion oftrapped gases, such as air and/or other gases, may be at least partiallyevacuated from between superabrasive element 110 and/or liner 140 andprotective leaching cup 230. For example, portions of side wall 234 maybe pushed outward away from superabrasive element 110 and liner 140 soas to facilitate evacuation of gases trapped within protective leachingcup 230.

By maintaining a seal between superabrasive element 110 and protectiveleaching cup 230 during leaching, portions of superabrasive element 110may be prevented or inhibited from being exposed to a leaching agentduring leaching, thereby preventing damage, such as corrosion damage, tocertain regions of superabrasive element 110, such as substrate 112.Additionally, various regions of superabrasive element 110, such assuperabrasive face 120, superabrasive edge 124, and/or at least aportion of superabrasive side surface 122 may not be covered byprotective leaching cup 230 and may remain exposed to a leaching agentduring leaching, enabling leaching of such regions to achieve a desiredleach depth configuration. According to some embodiments, as illustratedin FIG. 8, at least a portion of superabrasive side surface 122extending between seal region 238 of protective leaching cup 230 andsuperabrasive edge 124 of superabrasive element 110 may be exposed to aleaching agent during leaching.

Liner 140, which surrounds at least a portion of superabrasive element110, including at least a portion of substrate 112, may additionallyprevent a leaching agent from contacting substrate 112 during and/orfollowing leaching. For example, pinholes, which may be formed inprotective leaching cup 230 during ejection of superabrasive element 110from a leaching apparatus following a leaching procedure, may allow aleaching agent to contact liner 140. Rear wall 142 of liner 140, whichis disposed between rear wall 232 of protective leaching cup 230 andrear surface 118 of superabrasive element 110, may inhibit or prevent aleaching agent, such as a leaching agent entering protective leachingcup 230 through rear wall 232, from contacting rear surface 118 ofsuperabrasive element 110. Rounded edge portion 149 and side wall 144 ofliner 230 may further prevent a leaching agent from contacting substratechamfer 128 and/or at least a portion of substrate side surface 116 ofsuperabrasive element 110. Accordingly, liner 140 may further inhibit orprevent damage, such as corrosion damage, to various regions ofsuperabrasive element 110, such as substrate 112, during and/orfollowing leaching.

FIGS. 9-14 illustrate exemplary liners surrounding superabrasiveelements according to various embodiments. Such exemplary liners may beutilized in various leaching assemblies as disclosed herein. As shown inFIG. 9, liner 340 may comprise a rear wall 342 and a side wall 344defining a cavity 348 configured to surround and/or contact at least aportion of superabrasive element 10. Additionally, liner 340 maycomprise a rounded edge portion 349 formed at an intersection of rearwall 342 and side wall 344. Rounded edge portion 349 may comprise anysuitable surface shape, such as, for example, an arcuate surface (e.g.,a radius, an ovoid shape, or any other rounded shape), multiple radii, ahoned edge, a combination arcuate and flat surface, or any combinationof the foregoing. Rear wall 342, side wall 344, and rounded edge portion349 may each be formed to any suitable thickness, without limitation.

Liner 340 may be formed of any suitable material. For example, liner 340may comprise a rigid or substantially rigid material. In someembodiments, liner 340 may comprise one or more metallic materials. Forexample, liner 340 may be formed of one or more refractory metalmaterials, such as niobium, tantalum, molybdenum, tungsten, rhenium,chromium, vanadium, hafnium, zirconium, and/or any other suitablemetallic material or alloy thereof. In additional embodiments, liner 340may comprise various other suitable metallic materials and/or alloysthereof, such as, for example, precious metals, platinum group metals(e.g., gold and/or platinum), iron, tin, copper, silver, bronze,aluminum, steel and/or steel alloys, or any alloys of one or more of theforegoing. In additional embodiments, liner 340 may comprise one or morepolymeric materials. For example, liner 340 may comprisepolytetrafluoroethylene (PTFE) and/or any other suitable polymer orresin, without limitation. Liner 340 may also comprise any othersuitable material or combination of materials, including, for example,ceramic, glass, a carbon material, a metallic material, a carbonallotrope material, a composite material, an oxide material, a carbidematerial, and/or any combination of the foregoing.

Liner 340 may be formed using any suitable technique. For example, liner340 may comprise a metallic material that is shaped through a molding,drawing, machining, milling, grinding, and/or any other suitablemetalworking or forming technique. According to some embodiments, agenerally disk-shaped blank (e.g., a niobium blank) may be subjected toa drawing operation. During such a drawing operation, a punch may beutilized to force the disk-shaped blank into a corresponding forming diecavity. In at least one embodiment, liner 340 may comprise a polymericmaterial that is shaped using, for example, a molding operation (e.g.,injection molding, blow molding, compression molding, drawing, etc.). Invarious embodiments, a combination of a metallic material, a polymericmaterial, and/or any other suitable material may also be utilized toform liner 340. For example, liner 340 may comprise a metallic material(e.g., niobium, steel, etc.) having one or more surfaces coated with apolymeric layer (e.g., PTFE) and/or other suitable material. In otherembodiments, liner 340 may be formed on superabrasive element 10 as acoating by spraying, dipping, polymerization, electroplating, chemicalvapor deposition, physical vapor deposition, and/or any suitable coatingtechnique, without limitation. Such a coating may be formed onsuperabrasive element 10 so as to have rounded edge portions formedadjacent more angular portions (e.g., chamfer 28) of superabrasiveelement 10.

Liner 340 may comprise any suitable size, shape, and geometry configuredto surround at least a portion of superabrasive element 10. In at leastone embodiment, portions of liner 340 may have a substantiallycylindrical outer periphery surrounding central axis 29, as illustratedin FIG. 9. Rear wall 342 and side wall 344 may define a cavity 348within liner 340. Cavity 348 may be shaped to surround at least aportion of superabrasive element 10. An opening 346 may be defined in aportion of liner 340 opposite rear wall 342 such that cavity 348 extendsbetween opening 346 and rear wall 342. According to at least oneembodiment, liner 340 may be sized to fit within an encapsulating regionof a protective leaching cup (e.g., encapsulating region 39 ofprotective leaching cup 30 in FIG. 6).

As shown in FIG. 9, superabrasive element 10 may be positioned withinliner 340 such that at least a portion of an outer periphery ofsuperabrasive element 10 is surrounded by protective liner 340. Forexample, superabrasive element 10 may be positioned within liner 340 sothat at least a portion of rear surface 18 of superabrasive element 10is adjacent rear wall 342 of liner 340 and/or so that at least a portionof side surface 15 of superabrasive element 10 is adjacent side wall 344of liner 340. For example, side wall 344 of liner 340 may be disposedadjacent substrate side surface 16. In at least one embodiment, sidewall 344 of liner 340 may extend adjacent substrate side surface 16 to aposition adjacent interface 26 between substrate 12 and superabrasivetable 14 of superabrasive element 10. According to certain embodiments,side wall 344 of liner 340 may additionally extend adjacent at least aportion of superabrasive table 14, as illustrated in FIG. 9.Accordingly, in addition to protecting substrate 12 of superabrasiveelement 10, liner 340 may inhibit or prevent a leaching agent fromcontacting at least a portion of interface 26 and/or superabrasive table14.

In some embodiments, superabrasive element 10 may contact side wall 344of liner 340. For example, superabrasive element 10 may be tightlysurrounded by liner 340 so as to secure liner 340 to superabrasiveelement 10. For example, liner 340 may be secured around superabrasiveelement 10 by press-fitting. According to some embodiments, liner 340may be bonded or otherwise adhered to at least a portion of side surface15 and/or at least a portion of rear surface 18 of superabrasive element10. In additional embodiments, superabrasive element 10 may be lesstightly (e.g., removably) surrounded by liner 340, thereby facilitatinginsertion and/or removal of superabrasive element 10 from liner 340. Insome embodiments, a gap 350 may be defined between rounded edge portion349 of liner 340 and chamfer 28 of superabrasive element 10. Forexample, when superabrasive element 10 is disposed within liner 340 suchthat element side surface 15 and rear surface 18 of superabrasiveelement 10 are respectively positioned adjacent side wall 344 and rearwall 342 of liner 340, chamfer 28 of superabrasive element 10 may bespaced away from an inner surface of rounded edge portion 349 so as todefine gap 350. According to some embodiments, liner 340 maycircumferentially surround and/or abut a peripheral portion ofsuperabrasive element 10 with respect to central axis 29. In at leastone embodiment, liner 340 may comprise one or more separate segmentsspaced circumferentially around at least a portion of superabrasiveelement 10.

FIG. 10 shows a liner 440 surrounding a superabrasive element 10,according to various embodiments. Liner 440 may comprise a rear wall 442and a side wall 444 defining a cavity 448 configured to surround and/orcontact at least a portion of superabrasive element 10. Additionally,liner 440 may comprise a rounded edge portion 449 formed at anintersection of rear wall 442 and side wall 444. Rounded edge portion449 may comprise any suitable surface shape, such as, for example, anarcuate surface (e.g., a radius, an ovoid shape, or any other roundedshape), multiple radii, a honed edge, a combination arcuate and flatsurface, or any combination of the foregoing. Rear wall 442, side wall444, and rounded edge portion 449 may each be formed to any suitablethickness, without limitation.

Liner 440 may be formed of any suitable material. For example, liner 440may comprise a rigid or substantially rigid material. In someembodiments, liner 440 may comprise one or more metallic materials. Forexample, liner 440 may be formed of one or more refractory metalmaterials, such as niobium, tantalum, molybdenum, tungsten, rhenium,chromium, vanadium, hafnium, zirconium, and/or any other suitablemetallic material or alloy thereof. In additional embodiments, liner 440may comprise various other suitable metallic materials and/or alloysthereof, such as, for example, precious metals, platinum group metals(e.g., gold and/or platinum), iron, tin, copper, silver, bronze,aluminum, steel and/or steel alloys, or any alloys of one or more of theforegoing. In additional embodiments, liner 440 may comprise one or morepolymeric materials. For example, liner 440 may comprisepolytetrafluoroethylene (PTFE) and/or any other suitable polymer orresin, without limitation. Liner 440 may also comprise any othersuitable material or combination of materials, including, for example,ceramic, glass, a carbon material, a metallic material, a carbonallotrope material, a composite material, an oxide material, a carbidematerial, and/or any combination of the foregoing.

Liner 440 may be formed using any suitable technique. For example, liner440 may comprise a metallic material that is shaped through a molding,drawing, machining, milling, grinding, and/or any other suitablemetalworking or forming technique. According to some embodiments, agenerally disk-shaped blank (e.g., a niobium blank) may be subjected toa drawing operation. During such a drawing operation, a punch may beutilized to force the disk-shaped blank into a corresponding forming diecavity. In at least one embodiment, liner 440 may comprise a polymericmaterial that is shaped using, for example, a molding operation (e.g.,injection molding, blow molding, compression molding, drawing, etc.). Invarious embodiments, a combination of a metallic material, a polymericmaterial, and/or any other suitable material may also be utilized toform liner 440. For example, liner 440 may comprise a metallic material(e.g., niobium, steel, etc.) having one or more surfaces coated with apolymeric layer (e.g., PTFE) and/or other suitable material. In otherembodiments, liner 440 may be formed on superabrasive element 10 as acoating by spraying, dipping, polymerization, electroplating, chemicalvapor deposition, physical vapor deposition, and/or any suitable coatingtechnique, without limitation. Such a coating may be formed onsuperabrasive element 10 so as to have rounded edge portions formedadjacent more angular portions (e.g., chamfer 28) of superabrasiveelement 10.

Liner 440 may comprise any suitable size, shape, and geometry configuredto surround at least a portion of superabrasive element 10. In at leastone embodiment, portions of liner 440 may have a substantiallycylindrical outer periphery surrounding central axis 29, as illustratedin FIG. 10. Rear wall 442 and side wall 444 may define a cavity 448within liner 440. Cavity 448 may be shaped to surround at least aportion of superabrasive element 10. An opening 446 may be defined in aportion of liner 440 opposite rear wall 442 such that cavity 448 extendsbetween opening 446 and rear wall 442. According to at least oneembodiment, liner 440 may be sized to fit within an encapsulating regionof a protective leaching cup (e.g., encapsulating region 39 ofprotective leaching cup 30 in FIG. 6).

As shown in FIG. 10, superabrasive element 10 may be positioned withinliner 440 such that at least a portion of an outer periphery ofsuperabrasive element 10 is surrounded by protective liner 440. Forexample, superabrasive element 10 may be positioned within liner 440 sothat at least a portion of rear surface 18 of superabrasive element 10is adjacent rear wall 442 of liner 440 and/or so that at least a portionof side surface 15 of superabrasive element 10 is adjacent side wall 444of liner 440. For example, side wall 444 of liner 440 may be disposedadjacent substrate side surface 16 of superabrasive element 10.

In some embodiments, superabrasive element 10 may contact side wall 444of liner 440. For example, superabrasive element 10 may be tightlysurrounded by liner 440 so as to secure liner 440 to superabrasiveelement 10. For example, liner 440 may be secured around superabrasiveelement 10 by press-fitting. According to some embodiments, liner 440may be bonded or otherwise adhered to at least a portion of side surface15 and/or rear surface 18 of superabrasive element 10. In additionalembodiments, superabrasive element 10 may be less tightly (e.g.,removably) surrounded by liner 440, thereby facilitating insertionand/or removal of superabrasive element 10 from liner 440. As shown inFIG. 10, liner 440 may additionally comprise a sloped surface 452extending between side wall 444 and rear wall 442 in an inner portion ofliner 440. When superabrasive element 10 is disposed within liner 440such that element side surface 15 and rear surface 18 of superabrasiveelement 10 are respectively positioned adjacent side wall 444 and rearwall 442 of liner 440, substrate chamfer 28 of superabrasive element 10may be located adjacent to and/or in contact with sloped surface 452 ofliner 440. According to at least one embodiment, sloped surface 452 maysubstantially conform to a shape of substrate chamfer 28. According tosome embodiments, liner 440 may circumferentially surround and/or abut aperipheral portion of superabrasive element 10 with respect to centralaxis 29. In at least one embodiment, liner 440 may comprise one or moreseparate segments spaced circumferentially around at least a portion ofsuperabrasive element 10.

FIG. 11 shows a liner 40 surrounding a superabrasive element 510,according to various embodiments. Liner 40 may be utilized forprocessing superabrasive elements having various surface configurationsformed at an intersection of a side surface and a rear surface. As shownin FIG. 11, superabrasive element 510 may comprise a superabrasive table514 affixed to or formed upon a substrate 512. Superabrasive table 514may be affixed to substrate 512 at interface 526. Superabrasive element510 may comprise a rear surface 518, a superabrasive face 520, and anelement side surface 515. In some embodiments, element side surface 515may include a substrate side surface 516 formed by substrate 512 and asuperabrasive side surface 522 formed by superabrasive table 514. Rearsurface 518 may be formed by substrate 512. Superabrasive element 510may also comprise a superabrasive face 520 and a superabrasive chamfer524 formed by superabrasive table 514.

According to various embodiments, superabrasive element 510 may alsocomprise a substrate edge 554 formed by substrate 512. In someembodiments, substrate edge 554 may comprise an angular and/or roundededge formed at the intersection of substrate side surface 516 and rearsurface 518. Any other suitable surface shape may also be formed at theintersection of substrate side surface 516 and rear surface 518,including, without limitation, an arcuate surface (e.g., a radius, anovoid shape, or any other rounded shape), a sharp edge, a honed edge,and/or combinations of the foregoing.

As shown in FIG. 11, a superabrasive element 510 may be positionedwithin liner 40 such that at least a portion of an outer periphery ofsuperabrasive element 510 is surrounded by protective liner 40. Forexample, superabrasive element 510 may be positioned within liner 40 sothat at least a portion of rear surface 518 of superabrasive element 510is near rear wall 42 of liner 40 and/or so that at least a portion ofside surface 515 of superabrasive element 510 is adjacent side wall 44of liner 40. For example, side wall 44 of liner 40 may be disposedadjacent substrate side surface 516.

In some embodiments, superabrasive element 510 may contact side wall 44of liner 40. For example, superabrasive element 510 may be tightlysurrounded by liner 40 so as to secure liner 40 to superabrasive element510. For example, liner 40 may be secured around superabrasive element510 by press-fitting. According to some embodiments, liner 40 may bebonded or otherwise adhered to at least a portion of side surface 515and/or rear surface 518 of superabrasive element 510. In additionalembodiments, superabrasive element 510 may be less tightly (e.g.,removably) surrounded by liner 40, thereby facilitating insertion and/orremoval of superabrasive element 510 from liner 40. When superabrasiveelement 510 is disposed within liner 40 such that element side surface515 and rear surface 518 of superabrasive element 510 are respectivelypositioned adjacent side wall 44 and/or near rear wall 42 of liner 40, agap 556 may be defined between rear wall 42 of liner 40 and rear surface518 of superabrasive element 510. In additional embodiments, an innersurface portion of liner 40 may be shaped such that rear surface 518 ofsuperabrasive element 510 is disposed adjacent to or in contact with atleast a portion of rear wall 42 of liner 40. For example, liner 40 maybe shaped to conform to at least a portion of element side surface 515,rear surface 518, and/or substrate edge 554. According to someembodiments, liner 540 may circumferentially surround and/or abut aperipheral portion of superabrasive element 10 with respect to centralaxis 29. In at least one embodiment, liner 540 may comprise one or moreseparate segments spaced circumferentially around at least a portion ofsuperabrasive element 10.

FIG. 12 shows a liner 640 surrounding a superabrasive element 10,according to various embodiments. Liner 640 may comprise a rear wall 642and a side wall 644 defining a cavity 648 configured to surround and/orcontact at least a portion of superabrasive element 10. Additionally,liner 640 may comprise a rounded edge portion 649 formed at anintersection of rear wall 642 and side wall 644. Rounded edge portion649 may comprise any suitable surface shape, such as, for example, anarcuate surface (e.g., a radius, an ovoid shape, or any other roundedshape), multiple radii, a honed edge, a combination arcuate and flatsurface, or any combination of the foregoing. Rear wall 642, side wall644, and rounded edge portion 649 may each be formed to any suitablethickness, without limitation. According to some embodiments, at leastone opening may be defined in liner 640 in addition to opening 646. Forexample, as shown in FIG. 12, an opening 657 may be defined in rear wall642. Opening 642 may be open to cavity 648.

Liner 640 may be formed of any suitable material. For example, liner 640may comprise a rigid or substantially rigid material. In someembodiments, liner 640 may comprise one or more metallic materials. Forexample, liner 640 may be formed of one or more refractory metalmaterials, such as niobium, tantalum, molybdenum, tungsten, rhenium,chromium, vanadium, hafnium, zirconium, and/or any other suitablemetallic material or alloy thereof. In additional embodiments, liner 640may comprise various other suitable metallic materials and/or alloysthereof, such as, for example, precious metals, platinum group metals(e.g., gold and/or platinum), iron, tin, copper, silver, bronze,aluminum, steel and/or steel alloys, or any alloys of one or more of theforegoing. In additional embodiments, liner 640 may comprise one or morepolymeric materials. For example, liner 640 may comprisepolytetrafluoroethylene (PTFE) and/or any other suitable polymer orresin, without limitation. Liner 640 may also comprise any othersuitable material or combination of materials, including, for example,ceramic, glass, a carbon material, a metallic material, a carbonallotrope material, a composite material, an oxide material, a carbidematerial, and/or any combination of the foregoing.

Liner 640 may be formed using any suitable technique. For example, liner640 may comprise a metallic material that is shaped through a molding,drawing, machining, milling, grinding, and/or any other suitablemetalworking or forming technique. According to some embodiments, agenerally disk-shaped blank (e.g., a niobium blank) may be subjected toa drawing operation. During such a drawing operation, a punch may beutilized to force the disk-shaped blank into a corresponding forming diecavity. In at least one embodiment, liner 640 may comprise a polymericmaterial that is shaped using, for example, a molding operation (e.g.,injection molding, blow molding, compression molding, drawing, etc.). Invarious embodiments, a combination of a metallic material, a polymericmaterial, and/or any other suitable material may also be utilized toform liner 640. For example, liner 640 may comprise a metallic material(e.g., niobium, steel, etc.) having one or more surfaces coated with apolymeric layer (e.g., PTFE) and/or other suitable material. In otherembodiments, liner 640 may be formed on superabrasive element 10 as acoating by spraying, dipping, polymerization, electroplating, chemicalvapor deposition, physical vapor deposition, and/or any suitable coatingtechnique, without limitation. Such a coating may be formed onsuperabrasive element 10 so as to have rounded edge portions formedadjacent more angular portions (e.g., chamfer 28) of superabrasiveelement 10.

Liner 640 may comprise any suitable size, shape, and geometry configuredto surround at least a portion of superabrasive element 10. In at leastone embodiment, portions of liner 640 may have a substantiallycylindrical outer periphery surrounding central axis 29, as illustratedin FIG. 12. Rear wall 642 and side wall 644 may define a cavity 648within liner 640. Cavity 648 may be shaped to surround at least aportion of superabrasive element 10. An opening 646 may be defined in aportion of liner 640 opposite rear wall 642 such that cavity 648 extendsbetween opening 646 and rear wall 642. According to at least oneembodiment, liner 640 may be sized to fit within an encapsulating regionof a protective leaching cup (e.g., encapsulating region 39 ofprotective leaching cup 30 in FIG. 6).

As shown in FIG. 12, superabrasive element 10 may be positioned withinliner 640 such that at least a portion of an outer periphery ofsuperabrasive element 10 is surrounded by protective liner 640. Forexample, superabrasive element 10 may be positioned within liner 640 sothat at least a portion of rear surface 18 of superabrasive element 10is adjacent rear wall 642 of liner 640 and/or so that at least a portionof side surface 15 of superabrasive element 10 is adjacent side wall 644of liner 640. For example, side wall 644 of liner 640 may be disposedadjacent substrate side surface 16.

In some embodiments, superabrasive element 10 may contact side wall 644of liner 640. For example, superabrasive element 10 may be tightlysurrounded by liner 640 so as to secure liner 640 to superabrasiveelement 10. For example, liner 640 may be secured around superabrasiveelement 10 by press-fitting. According to some embodiments, liner 640may be bonded or otherwise adhered to at least a portion of side surface15 and/or at least a portion of rear surface 18 of superabrasive element10. In additional embodiments, superabrasive element 10 may be lesstightly (e.g., removably) surrounded by liner 640, thereby facilitatinginsertion and/or removal of superabrasive element 10 from liner 640.

In some embodiments, a gap 650 may be defined between rounded edgeportion 649 of liner 640 and chamfer 28 of superabrasive element 10. Forexample, when superabrasive element 10 is disposed within liner 640 suchthat element side surface 15 and rear surface 18 of superabrasiveelement 10 are respectively positioned adjacent side wall 644 and rearwall 642 of liner 640, chamfer 28 of superabrasive element 10 may bespaced away from an inner surface of rounded edge portion 649 so as todefine gap 650. According to some embodiments, opening 657, which isdefined in liner 640 so as to be open to cavity 648, may facilitateloading of superabrasive element 10 into liner 640 and/or may preventexcess gases and/or fluids from becoming trapped between liner 640 andsuperabrasive element 10. According to some embodiments, liner 640 maycircumferentially surround and/or abut a peripheral portion ofsuperabrasive element 10 with respect to central axis 29. In at leastone embodiment, liner 640 may comprise one or more separate segmentsspaced circumferentially around at least a portion of superabrasiveelement 10.

FIG. 13 shows a liner 740 surrounding a portion of superabrasive element10, according to various embodiments. Liner 740 may comprise a rear wall742 and a side wall 744 defining a cavity 748 configured to surroundand/or contact at least a portion of superabrasive element 10.Additionally, liner 740 may comprise a rounded edge portion 749 formedat an intersection of rear wall 742 and side wall 744. Rounded edgeportion 749 may comprise any suitable surface shape, such as, forexample, an arcuate surface (e.g., a radius, an ovoid shape, or anyother rounded shape), multiple radii, a honed edge, a combinationarcuate and flat surface, or any combination of the foregoing. Rear wall742, side wall 744, and rounded edge portion 749 may each be formed toany suitable thickness, without limitation. According to someembodiments, an opening 757 may be defined in rear wall 742. Opening 757may be open to cavity 748.

Liner 740 may be formed of any suitable material. For example, liner 740may comprise a rigid or substantially rigid material. In someembodiments, liner 740 may comprise one or more metallic materials. Forexample, liner 740 may be formed of one or more refractory metalmaterials, such as niobium, tantalum, molybdenum, tungsten, rhenium,chromium, vanadium, hafnium, zirconium, and/or any other suitablemetallic material or alloy thereof. In additional embodiments, liner 740may comprise various other suitable metallic materials and/or alloysthereof, such as, for example, precious metals, platinum group metals(e.g., gold and/or platinum), iron, tin, copper, silver, bronze,aluminum, steel and/or steel alloys, or any alloys of one or more of theforegoing. In additional embodiments, liner 740 may comprise one or morepolymeric materials. For example, liner 740 may comprisepolytetrafluoroethylene (PTFE) and/or any other suitable polymer orresin, without limitation. Liner 740 may also comprise any othersuitable material or combination of materials, including, for example,ceramic, glass, a carbon material, a metallic material, a carbonallotrope material, a composite material, an oxide material, a carbidematerial, and/or any combination of the foregoing.

Liner 740 may be formed using any suitable technique. For example, liner740 may comprise a metallic material that is shaped through a molding,drawing, machining, milling, grinding, and/or any other suitablemetalworking or forming technique. According to some embodiments, agenerally disk-shaped blank (e.g., a niobium blank) may be subjected toa drawing operation. During such a drawing operation, a punch may beutilized to force the disk-shaped blank into a corresponding forming diecavity. In at least one embodiment, liner 740 may comprise a polymericmaterial that is shaped using, for example, a molding operation (e.g.,injection molding, blow molding, compression molding, drawing, etc.). Invarious embodiments, a combination of a metallic material, a polymericmaterial, and/or any other suitable material may also be utilized toform liner 740. For example, liner 740 may comprise a metallic material(e.g., niobium, steel, etc.) having one or more surfaces coated with apolymeric layer (e.g., PTFE) and/or other suitable material. In otherembodiments, liner 740 may be formed on superabrasive element 10 as acoating by spraying, dipping, polymerization, electroplating, chemicalvapor deposition, physical vapor deposition, and/or any suitable coatingtechnique, without limitation. Such a coating may be formed onsuperabrasive element 10 so as to have rounded edge portions formedadjacent more angular portions (e.g., chamfer 28) of superabrasiveelement 10.

Liner 740 may comprise any suitable size, shape, and geometry configuredto surround at least a portion of superabrasive element 10. In at leastone embodiment, portions of liner 740 may have a substantiallycylindrical and/or annular outer periphery surrounding central axis 29,as illustrated in FIG. 13. Rear wall 742 and side wall 744 may define acavity 748 within liner 740. Cavity 748 may be shaped to surround atleast a portion of superabrasive element 10. An opening 746 may bedefined in a portion of liner 740 opposite rear wall 742 such thatcavity 748 extends between opening 746 and rear wall 742. According toat least one embodiment, liner 740 may be sized to fit within anencapsulating region of a protective leaching cup (e.g., encapsulatingregion 39 of protective leaching cup 30 in FIG. 6).

As shown in FIG. 13, superabrasive element 10 may be positioned withinliner 740 such that at least a portion of an outer periphery ofsuperabrasive element 10 is surrounded by protective liner 740. Forexample, superabrasive element 10 may be positioned within liner 740 sothat at least a portion of rear surface 18 of superabrasive element 10is adjacent rear wall 742 of liner 740 and/or so that at least a portionof side surface 15 of superabrasive element 10 is adjacent side wall 744of liner 740. For example, side wall 744 of liner 740 may be disposedadjacent substrate side surface 16. In at least one embodiment, sidewall 744 of liner 740 may extend adjacent substrate side surface 16 ofsuperabrasive element 10. As shown in FIG. 13, side wall 744 of liner740 may extend along a portion of substrate side surface 16 ofsuperabrasive element 10 and/or rear wall 742 of liner 740 may extendalong a portion of rear surface 18 of superabrasive element 10. Forexample, side wall 744 may extend to a region adjacent to or nearchamfer 28 and/or rear wall 742 may extend to a region adjacent to ornear chamfer 28 of superabrasive element 10. In some embodiments, sidewall 744 of liner 740 may abut chamfer 28 and/or rear wall 742 of liner740 may abut chamfer 28 of superabrasive element 10.

In some embodiments, superabrasive element 10 may contact side wall 744of liner 740. For example, superabrasive element 10 may be tightlysurrounded by liner 740 so as to secure liner 740 to superabrasiveelement 10. For example, liner 740 may be secured around superabrasiveelement 10 by press-fitting. According to some embodiments, liner 740may be bonded or otherwise adhered to at least a portion of side surface15 and/or at least a portion of rear surface 18 of superabrasive element10. In additional embodiments, superabrasive element 10 may be lesstightly (e.g., removably) surrounded by liner 740, thereby facilitatinginsertion and/or removal of superabrasive element 10 from liner 740.

In some embodiments, a gap 750 may be defined between rounded edgeportion 749 of liner 740 and chamfer 28 of superabrasive element 10. Forexample, when superabrasive element 10 is disposed within liner 740 suchthat element side surface 15 and rear surface 18 of superabrasiveelement 10 are respectively positioned adjacent side wall 744 and rearwall 742 of liner 740, chamfer 28 of superabrasive element 10 may bespaced away from an inner surface of rounded edge portion 749 so as todefine gap 750. According to some embodiments, opening 757, which isdefined in liner 740 so as to be open to cavity 748, may facilitateloading of superabrasive element 10 into liner 740 and/or may preventexcess gases and/or fluids from becoming trapped between liner 740 andsuperabrasive element 10. According to some embodiments, liner 740 maycircumferentially surround and/or abut a peripheral portion ofsuperabrasive element 10 with respect to central axis 29. In at leastone embodiment, liner 740 may comprise one or more separate segmentsspaced circumferentially around at least a portion of superabrasiveelement 10.

FIG. 14 shows a liner 840 surrounding and/or abutting a portion ofsuperabrasive element 10, according to various embodiments. Liner 840may comprise a surface, such as sloped surface 852, configured tosurround and/or abut at least a portion of superabrasive element 10.Additionally, liner 840 may comprise a rounded edge portion 849 formedadjacent or near sloped surface 852. Rounded edge portion 849 maycomprise any suitable surface shape, such as, for example, an arcuatesurface (e.g., a radius, an ovoid shape, or any other rounded shape),multiple radii, a honed edge, a combination arcuate and flat surface, orany combination of the foregoing. Sloped surface 852 and rounded edgeportion 849 may each be formed to any suitable thickness, withoutlimitation. According to some embodiments, an opening 857 may be definedin liner 840.

Liner 840 may be formed of any suitable material. For example, liner 840may comprise a rigid or substantially rigid material. In someembodiments, liner 840 may comprise one or more metallic materials. Forexample, liner 840 may be formed of one or more refractory metalmaterials, such as niobium, tantalum, molybdenum, tungsten, rhenium,chromium, vanadium, hafnium, zirconium, and/or any other suitablemetallic material or alloy thereof. In additional embodiments, liner 840may comprise various other suitable metallic materials and/or alloysthereof, such as, for example, precious metals, platinum group metals(e.g., gold and/or platinum), iron, tin, copper, silver, bronze,aluminum, steel and/or steel alloys, or any alloys of one or more of theforegoing. In additional embodiments, liner 840 may comprise one or morepolymeric materials. For example, liner 840 may comprisepolytetrafluoroethylene (PTFE) and/or any other suitable polymer orresin, without limitation. Liner 840 may also comprise any othersuitable material or combination of materials, including, for example,ceramic, glass, a carbon material, a metallic material, a carbonallotrope material, a composite material, an oxide material, a carbidematerial, and/or any combination of the foregoing.

Liner 840 may be formed using any suitable technique. For example, liner840 may comprise a metallic material that is shaped through a molding,drawing, machining, milling, grinding, and/or any other suitablemetalworking or forming technique. According to some embodiments, agenerally disk-shaped blank (e.g., a niobium blank) may be subjected toa drawing operation. During such a drawing operation, a punch may beutilized to force the disk-shaped blank into a corresponding forming diecavity. In at least one embodiment, liner 840 may comprise a polymericmaterial that is shaped using, for example, a molding operation (e.g.,injection molding, blow molding, compression molding, drawing, etc.). Invarious embodiments, a combination of a metallic material, a polymericmaterial, and/or any other suitable material may also be utilized toform liner 840. For example, liner 840 may comprise a metallic material(e.g., niobium, steel, etc.) having one or more surfaces coated with apolymeric layer (e.g., PTFE) and/or other suitable material. In otherembodiments, liner 840 may be formed on superabrasive element 10 as acoating by spraying, dipping, polymerization, electroplating, chemicalvapor deposition, physical vapor deposition, and/or any suitable coatingtechnique, without limitation. Such a coating may be formed onsuperabrasive element 10 so as to have rounded edge portions formedadjacent more angular portions (e.g., chamfer 28) of superabrasiveelement 10.

Liner 840 may comprise any suitable size, shape, and geometry configuredto surround and/or abut at least a portion of superabrasive element 10.In at least one embodiment, portions of liner 840 may have asubstantially annular outer periphery surrounding central axis 29, asillustrated in FIG. 14. According to at least one embodiment, liner 840may be sized to fit within an encapsulating region of a protectiveleaching cup (e.g., encapsulating region 39 of protective leaching cup30 in FIG. 6).

As shown in FIG. 14, at least a portion of superabrasive element 10 maybe positioned within and/or abutting liner 840 such that at least aportion of an outer periphery of superabrasive element 10 is surroundedby protective liner 840. For example, superabrasive element 10 may bepositioned within liner 840 so that at least a portion of superabrasiveelement 10 (e.g., substrate chamfer 28) is adjacent sloped surface 852of liner 840. According to certain embodiments, protective liner 840 maybe shaped to abut various portions of a superabrasive element, such asan angular or rounded intersection or edge defined by a side surface, arear surface, and/or a chamfered surface (e.g., substrate edge 149 ofsuperabrasive element 110 illustrated in FIGS. 7 and 8).

In some embodiments, at least a portion of superabrasive element 10 maybe tightly surrounded by liner 840 so as to secure liner 840 tosuperabrasive element 10. According to some embodiments, liner 840 maybe bonded or otherwise adhered to at least a portion of side surface 15,rear surface 18, and/or substrate chamfer 28 of superabrasive element10. In additional embodiments, superabrasive element 10 may be lesstightly (e.g., removably) surrounded and/or abutted by liner 840,thereby facilitating insertion and/or removal of superabrasive element10 from liner 840. When superabrasive element 10 is disposed withinand/or abutting liner 840, substrate chamfer 28 of superabrasive element10 may be located adjacent to and/or in contact with sloped surface 852of liner 840. According to at least one embodiment, sloped surface 852may substantially conform to a shape of substrate chamfer 28. Accordingto some embodiments, liner 840 may circumferentially surround and/orabut a peripheral portion of superabrasive element 10 with respect tocentral axis 29. In at least one embodiment, liner 840 may comprise oneor more separate segments spaced circumferentially around at least aportion of superabrasive element 10.

FIG. 15 is a perspective view of an exemplary drill bit 80 according toat least one embodiment. Drill bit 80 may represent any type or form ofearth-boring or drilling tool, including, for example, a rotary drillbit. As illustrated in FIG. 15, drill bit 80 may comprise a bit body 81having a longitudinal axis 84. Bit body 81 may define a leading endstructure for drilling into a subterranean formation by rotating bitbody 81 about longitudinal axis 84 and applying weight to bit body 81.Bit body 81 may include radially and longitudinally extending blades 79with leading faces 82 and a threaded pin connection 83 for connectingbit body 81 to a drill string.

At least one superabrasive element 10 and/or at least one superabrasiveelement 310 may be coupled to bit body 81. For example, as shown in FIG.15, a plurality of superabrasive elements 10 may be coupled to blades79. Drill bit 80 may utilize any of the disclosed superabrasive elements10 as cutting elements. Circumferentially adjacent blades 79 may defineso-called junk slots 85 therebetween. Junk slots 85 may be configured tochannel debris, such as rock or formation cuttings, away fromsuperabrasive elements 10 during drilling. Drill bit 80 may also includea plurality of nozzle cavities 86 for communicating drilling fluid fromthe interior of drill bit 80 to superabrasive elements 10.

FIG. 15 depicts an example of a drill bit 80 that employs at least onecutting element 10. Drill bit 80 may additionally represent any numberof earth-boring tools or drilling tools, including, for example, corebits, roller-cone bits, fixed-cutter bits, eccentric bits, bicenterbits, reamers, reamer wings, and/or any other downhole tools comprisingsuperabrasive cutting elements and/or discs, without limitation.Superabrasive elements 10 disclosed herein may also be utilized inapplications other than cutting technology. For example, embodiments ofsuperabrasive elements 10 disclosed herein may also form all or part ofheat sinks, wire dies, bearing elements, cutting elements, cuttinginserts (e.g., on a roller cone type drill bit), machining inserts, orany other article of manufacture, as known in the art. According to someexamples, superabrasive elements 10, as disclosed herein, may beemployed in medical device applications, including, without limitation,hip joints, back joints, or any other suitable medical joints. Thus,superabrasive elements 10, as disclosed herein, may be employed in anysuitable article of manufacture. Other examples of articles ofmanufacture that may incorporate superabrasive elements as disclosedherein may be found in U.S. Pat. Nos. 4,811,801; 4,268,276; 4,468,138;4,738,322; 4,913,247; 5,016,718; 5,092,687; 5,120,327; 5,135,061;5,154,245; 5,460,233; 5,544,713; and 6,793,681, the disclosure of eachof which is incorporated herein, in its entirety, by this reference.

In additional embodiments, a rotor and a stator, such as a rotor and astator used in a thrust bearing apparatus, may each include at least onesuperabrasive element according to the embodiments disclosed herein. Byway of example, U.S. Pat. Nos. 4,410,054; 4,560,014; 5,364,192;5,368,398; and 5,480,233, the disclosure of each of which isincorporated herein, in its entirety, by this reference, disclosesubterranean drilling systems that include bearing apparatuses utilizingsuperabrasive elements 10 as disclosed herein.

FIG. 16 is partial cross-sectional perspective view of an exemplarythrust-bearing apparatus 87 according to at least one embodiment.Thrust-bearing apparatus 87 may utilize any of the disclosedsuperabrasive elements 10 and/or superabrasive elements 310 as bearingelements. Thrust-bearing apparatus 87 may also include bearingassemblies 88A and 88B. Each of bearing assembly 88A and 88B may includea support ring 89 fabricated from a material, such as steel, stainlesssteel, or any other suitable material, without limitation.

Each support ring 89 may include a plurality of recesses 90 configuredto receive corresponding superabrasive elements 10. Each superabrasiveelement 10 may be mounted to a corresponding support ring 89 within acorresponding recess 90 by brazing, welding, press-fitting, usingfasteners, or any another suitable mounting technique, withoutlimitation. In at least one embodiment, one or more of superabrasiveelements 10 may be configured according to any of the superabrasiveelement embodiments described herein. For example, each superabrasiveelement 10 may include a substrate 12 and a superabrasive table 14comprising a PCD material. Each superabrasive table 14 may form asuperabrasive face 20 that is utilized as a bearing surface.

Superabrasive faces 20 of bearing assembly 88A may bear against opposingsuperabrasive faces 20 of bearing assembly 88B in thrust-bearingapparatus 87, as illustrated in FIG. 16. For example, bearing assembly88A of thrust-bearing apparatus 87 may be termed a “rotor.” The rotormay be operably coupled to a rotational shaft. Bearing assembly 88B ofthrust-bearing apparatus 87 may be held substantially stationaryrelative to the bearing assembly 88A and may be termed a “stator.”

FIG. 17 is a perspective view of a radial bearing apparatus 91 accordingto another embodiment. Radial bearing apparatus 91 may utilize any ofthe disclosed superabrasive element embodiments as bearing elements 10Aand 10B. Radial bearing apparatus 91 may include an inner race 92Apositioned generally within an outer race 92B. Inner race 92A mayinclude a plurality of bearing elements 10A affixed thereto, and outerrace 92B may include a plurality of corresponding bearing elements 10Baffixed thereto. One or more of bearing elements 10A and 10B may beconfigured in accordance with any of the superabrasive elementembodiments disclosed herein.

Inner race 92A may be positioned generally within outer race 92B. Thus,inner race 92A and outer race 92B may be configured such that bearingsurfaces 20A defined by bearing elements 10A and bearing surfaces 20Bdefined by bearing elements 10B may at least partially contact oneanother and move relative to one another as inner race 92A and outerrace 92B rotate relative to each other. According to variousembodiments, thrust-bearing apparatus 87 and/or radial bearing apparatus91 may be incorporated into a subterranean drilling system.

FIG. 18 is a partial cross-sectional perspective view of an exemplarysubterranean drilling system 93 that includes a thrust-bearing apparatus87, as shown in FIG. 16, according to at least one embodiment. Thesubterranean drilling system 93 may include a housing 94 enclosing adownhole drilling motor 95 (i.e., a motor, turbine, or any othersuitable device capable of rotating an output shaft, without limitation)that is operably connected to an output shaft 96.

The thrust-bearing apparatus 87 shown in FIG. 16 may be operably coupledto downhole drilling motor 95. A rotary drill bit 97, such as a rotarydrill bit configured to engage a subterranean formation and drill aborehole, may be connected to output shaft 96. As illustrated in FIG.18, rotary drill bit 97 may be a roller cone bit comprising a pluralityof roller cones 98. According to additional embodiments, rotary drillbit 97 may comprise any suitable type of rotary drill bit, such as, forexample, a so-called fixed-cutter drill bit. As a borehole is drilledusing rotary drill bit 97, pipe sections may be connected tosubterranean drilling system 93 to form a drill string capable ofprogressively drilling the borehole to a greater depth within asubterranean formation.

A thrust-bearing assembly 88A in thrust-bearing apparatus 87 may beconfigured as a rotor that is attached to output shaft 96 and athrust-bearing assembly 88B in thrust-bearing apparatus 87 may beconfigured as a stator. During a drilling operation using subterraneandrilling system 93, the rotor may rotate in conjunction with outputshaft 96 and the stator may remain substantially stationary relative tothe rotor.

According to various embodiments, drilling fluid may be circulatedthrough downhole drilling motor 95 to generate torque and effectrotation of output shaft 96 and rotary drill bit 97 attached thereto sothat a borehole may be drilled. A portion of the drilling fluid may alsobe used to lubricate opposing bearing surfaces of superabrasive elements10 on thrust-bearing assemblies 88A and 88B.

FIG. 19 illustrates an exemplary method 400 for processing apolycrystalline diamond element according to at least one embodiment. Asshown in FIG. 19, a polycrystalline diamond element may be provided(process 902). In some embodiments, a superabrasive element 10 maycomprise a superabrasive table 14 affixed to or formed upon a substrate12. The polycrystalline diamond element may comprise a rear surfaceopposite the cutting face and a side surface extending between thecutting face and the rear surface in a direction substantially parallelto a central axis of the polycrystalline diamond element. For example,as illustrated in FIGS. 1 and 2, superabrasive element 10 may comprise asuperabrasive face 20, a rear surface 18, and an element side surface15.

The polycrystalline diamond element, a liner, and a protective leachingcup may be assembled such that the liner is disposed between thepolycrystalline diamond element and the protective leaching cup.(process 904). For example, superabrasive element 10 may be positionedwithin a liner 40 as illustrated in FIG. 5. Superabrasive element 10 maybe positioned within liner 40 such that at least a portion of an outerperiphery of superabrasive element 10 is surrounded by protective liner40. For example, superabrasive element 10 may be positioned within liner40 so that at least a portion of rear surface 18 of superabrasiveelement 10 is adjacent rear wall 42 of liner 40 and/or so that at leasta portion of side surface 15, such as substrate side surface 16, isadjacent side wall 44 of liner 40. Superabrasive element 10 and liner 40may be positioned within protective leaching cup 30 as illustrated inFIG. 6. The protective leaching cup may include a seal region contactinga portion of a side surface of the polycrystalline diamond element. Forexample, protective leaching cup 30 may comprise a seal region 38 thatcontacts an element side surface 18 of superabrasive 10, as illustratedin FIGS. 4 and 6.

At least a portion of the polycrystalline diamond element may then beexposed to a leaching agent (process 906). For example, as shown in FIG.5, superabrasive element 10 may be positioned within protective leachingcup 30 so that portions of superabrasive table 14, such as superabrasiveface 20 and/or superabrasive chamfer 24, are not covered by protectiveleaching cup 30. Superabrasive element 10 and protective leaching cup 30may then be exposed to a leaching agent in any suitable manner. Forexample, superabrasive element 10 and protective leaching cup 30 may beat least partially submerged in a leaching agent that is suitable forleaching various materials from the exposed portions of superabrasivetable 14. In at least one embodiment, a corrosive leaching agent may beused to remove a metal-solvent catalyst from interstitial spaces betweendiamond grains in superabrasive table 14. According to variousembodiments, the leaching agent may comprise various solvents, acids,and/or other suitable reagents, including, without limitation, water,peroxide, nitric acid, hydrofluoric acid, and/or hydrochloric acid.Superabrasive element 10 may be exposed to the leaching agent for anysuitable period of time. For example, superabrasive element 10 may beexposed to the leaching agent until various interstitial materials, suchas, for example, a metal-solvent catalyst, are removed fromsuperabrasive table 14 to a desired depth or degree.

The preceding description has been provided to enable others skilled inthe art to best utilize various aspects of the exemplary embodimentsdescribed herein. This exemplary description is not intended to beexhaustive or to be limited to any precise form disclosed. Manymodifications and variations are possible without departing from thespirit and scope of the instant disclosure. It is desired that theembodiments described herein be considered in all respects illustrativeand not restrictive and that reference be made to the appended claimsand their equivalents for determining the scope of the instantdisclosure.

Unless otherwise noted, the terms “a” or “an,” as used in thespecification and claims, are to be construed as meaning “at least oneof.” In addition, for ease of use, the words “including” and “having,”as used in the specification and claims, are interchangeable with andhave the same meaning as the word “comprising.”

What is claimed is:
 1. A polycrystalline diamond element leachingassembly, comprising: a polycrystalline diamond element; a protectiveleaching cup surrounding at least a portion of the polycrystallinediamond element, the protective leaching cup comprising a seal regioncontacting a portion of the polycrystalline diamond element; a linerpositioned between a portion of the polycrystalline diamond element andthe protective leaching cup, wherein: the protective leaching cupcomprises an encapsulating region surrounding the liner; the seal regionof the protective leaching cup has a smaller diameter than theencapsulating region of the protective leaching cup.
 2. Thepolycrystalline diamond element leaching assembly of claim 1, whereinthe liner comprises: a side wall; a rear wall opposite an openingdefined in the liner; a rounded edge portion at the intersection of theside wall and the rear wall.
 3. The polycrystalline diamond elementleaching assembly of claim 2, wherein: the polycrystalline diamondelement comprises: a cutting face; a rear surface opposite the cuttingface; a side surface extending between the cutting face and the rearsurface; the liner surrounds at least a portion of the polycrystallinediamond element such that: the side wall of the liner is adjacent aportion of the side surface of the polycrystalline diamond element; therear wall of the liner is adjacent a portion of the rear surface of thepolycrystalline diamond element; a gap is defined between the roundededge portion of the liner and the polycrystalline diamond element. 4.The polycrystalline diamond element leaching assembly of claim 3,wherein: the polycrystalline diamond element comprises a chamfer at theintersection of the side surface and the rear surface; the gap isdefined between the rounded edge portion of the liner and the chamfer ofthe polycrystalline diamond element.
 5. The polycrystalline diamondelement leaching assembly of claim 3, wherein the liner contacts atleast one of the side surface of the polycrystalline diamond element andthe rear surface of the polycrystalline diamond element.
 6. Thepolycrystalline diamond element leaching assembly of claim 3, whereinthe seal region of the protective leaching cup circumferentiallycontacts a portion of the side surface of the polycrystalline diamondelement.
 7. The polycrystalline diamond element leaching assembly ofclaim 1, wherein the polycrystalline diamond element comprises: asubstrate; a polycrystalline diamond table bonded to the substrate. 8.The polycrystalline diamond element leaching assembly of claim 7,wherein the encapsulating region of the protective leaching cupsurrounds the substrate of the polycrystalline diamond element.
 9. Thepolycrystalline diamond element leaching assembly of claim 7, whereinthe liner surrounds at least a portion of the substrate of thepolycrystalline diamond element.
 10. The polycrystalline diamond elementleaching assembly of claim 7, wherein the liner is adjacent a portion ofthe polycrystalline diamond table of the polycrystalline diamondelement.
 11. A leaching assembly, comprising: a protective leaching cupconfigured to surround at least a portion of a polycrystalline diamondelement; a liner configured to be positioned between a portion of thepolycrystalline diamond element and the protective leaching cup,wherein: the protective leaching cup comprises: a seal region that isconfigured to contact a portion of the polycrystalline diamond element;an encapsulating region that is configured to surround the liner; theseal region of the protective leaching cup has a smaller diameter thanthe encapsulating region of the protective leaching cup.
 12. Theleaching assembly of claim 11, wherein the liner comprises: a side wall;a rear wall opposite an opening defined in the liner; a rounded edgeportion at the intersection of the side wall and the rear wall.
 13. Theleaching assembly of claim 12, wherein the liner is configured tosurround at least the portion of the polycrystalline diamond elementsuch that: the side wall of the liner is adjacent a side surface of thepolycrystalline diamond element; the rear wall of the liner is adjacenta rear surface of the polycrystalline diamond element; a gap is definedbetween the rounded edge portion of the liner and the polycrystallinediamond element.
 14. The leaching assembly of claim 13, wherein theliner is configured to contact at least one of the side surface of thepolycrystalline diamond element and the rear surface of thepolycrystalline diamond element.
 15. The polycrystalline diamond elementleaching assembly of claim 13, wherein the seal region of the protectiveleaching cup circumferentially contacts a portion of the side surface ofthe polycrystalline diamond element.
 16. The leaching assembly of claim12, wherein the protective leaching cup comprises a side wall having alength that exceeds a length of the side wall of the liner.
 17. Theleaching assembly of claim 11, wherein the liner comprises asubstantially rigid material.
 18. The leaching assembly of claim 11,wherein the liner comprises at least one of a metallic material and apolymeric material.
 19. A method of processing a polycrystalline diamondelement, the method comprising: providing a polycrystalline diamondelement; assembling the polycrystalline diamond element, a liner, and aprotective leaching cup such that the liner is disposed between aportion of the polycrystalline diamond element and the protectiveleaching cup, the protective leaching cup comprising: a seal regioncontacting a portion of the polycrystalline diamond element; anencapsulating region surrounding the liner; exposing at least a portionof the polycrystalline diamond element to a leaching agent; wherein theseal region of the protective leaching cup has a smaller diameter thanthe encapsulating region of the protective leaching cup.
 20. The methodof claim 19, wherein assembling the polycrystalline diamond element, theliner, and the protective leaching cup further comprises positioning theliner and the polycrystalline diamond element in the protective leachingcup such that the encapsulating region surrounds the liner.